U.S. patent application number 14/410057 was filed with the patent office on 2016-10-20 for corrugated pallet constructed of folded, interlocked blanks and method.
This patent application is currently assigned to DESIGN PALLETS, INC.. The applicant listed for this patent is DESIGN PALLETS, INC.. Invention is credited to Douglas A. OLVEY, James L. SKETO.
Application Number | 20160304240 14/410057 |
Document ID | / |
Family ID | 48948483 |
Filed Date | 2016-10-20 |
United States Patent
Application |
20160304240 |
Kind Code |
A1 |
OLVEY; Douglas A. ; et
al. |
October 20, 2016 |
CORRUGATED PALLET CONSTRUCTED OF FOLDED, INTERLOCKED BLANKS AND
METHOD
Abstract
An interlock for the top and bottom members of a
foldably-constructed pallet and a method of assembling a pallet
wherein the top and bottom members are interlocked. By folding
straps around the corners of the pallet, either from one sidewall
of the pallet around the corner to the adjacent sidewall or from
the top of the pallet to the bottom (and optionally from the bottom
of the pallet to the top), and anchoring the end of the strap to
the adjacent sidewall or the bottom member of the pallet (and if a
second strap folded from the bottom member to the top member is
utilized, to the top member), the load-bearing capacity of the
pallet is substantially increased.
Inventors: |
OLVEY; Douglas A.;
(Longwood, FL) ; SKETO; James L.; (Mableton,
GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DESIGN PALLETS, INC. |
APOPKA |
FL |
US |
|
|
Assignee: |
DESIGN PALLETS, INC.
APOPKA
FL
|
Family ID: |
48948483 |
Appl. No.: |
14/410057 |
Filed: |
June 26, 2013 |
PCT Filed: |
June 26, 2013 |
PCT NO: |
PCT/US2013/048007 |
371 Date: |
March 8, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61664827 |
Jun 27, 2012 |
|
|
|
61665358 |
Jun 28, 2012 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 19/0014 20130101;
B65D 19/38 20130101; B65D 2519/00019 20130101; B65D 2519/00273
20130101; B65D 2519/00567 20130101; B65D 19/0012 20130101; B65D
2519/00054 20130101; B65D 2519/00318 20130101; B65D 2519/00412
20130101; B65D 2519/00407 20130101; B65D 2519/00288 20130101 |
International
Class: |
B65D 19/00 20060101
B65D019/00; B65D 19/38 20060101 B65D019/38 |
Claims
1. A method of resisting torsional force exerted on a force
resisting structure comprised of top and bottom substantially
planar members, either or both of the top and bottom planar members
having folded portions forming sidewalls when and assembled to each
other in nested relation, comprising the steps of: folding a strap
formed integrally with the bottom member into contact with the top
member; inserting a tab formed on the end of the strap into a cut
formed on the top member; and retaining the tab formed on the end
of the strap in the cut.
2. The method of claim 1 wherein a strap formed integrally with the
top member is folded into contact with the bottom member for
inserting a tab formed on the end of the strap into and retaining
within a cut formed on the bottom member.
3. The method of claim 1 wherein the tab formed on the end of the
strap is driven through the cut by a mandrel that engages the
strap.
4. The method of claim 1 wherein the tab formed on the end of the
strap is retained in the cut by a mechanical fastener.
5. The method of claim 1 wherein the tab formed on the end of the
strap is retained in the cut by contact between the tab and the
material comprising the top member that is deflected by insertion
of the tab into the cut.
6. The method of claim 1 wherein the tab is retained in the cut by
engagement of the material comprising the top member by notches
formed in the strap.
7. The method of claim 1 wherein the strap is folded into contact
with the top side of the top member.
8. The method of claim 7 wherein the cut formed on the top member
is formed on the top side of the top member.
9. The method of claim 1 additionally comprising the steps of:
folding a strap formed integrally with the top member into contact
with the bottom member; inserting a tab formed on the end of the
top member strap into a cut formed on the bottom member; and
retaining the tab formed on the end of the top member strap in the
cut formed in the bottom member.
10. The method of claim 10 wherein the strap formed integrally with
the top member is folded into contact with the bottom member on one
side of the corner formed by the sidewalls of the top and bottom
members and the strap formed integrally with the bottom member is
folded into contact with the top member on the other side of the
corner formed by the sidewalls of the top and bottom members.
11. An interlock for the top and bottom members of a
foldably-constructed pallet comprising: a strap integral with the
material comprising one or both of the top and bottom members of a
foldably-constructed pallet, one or both of the top or bottom
members being folded to form sidewalls when assembled to each other
to form a pallet; a locking formation formed on the end of said
strap; a knife cut in the material comprising the opposite bottom
or top member for receiving the locking formation, said strap being
folded over the sidewall and into contact with the opposite bottom
or top member with the locking formation inserted into the knife
cut at the corner of the pallet.
12. The interlock of claim 11 wherein a portion of the material
comprising the top or bottom members bears against the locking
formation when the locking formation is inserted into the knife
cut.
13. The interlock of claim 11 additionally comprising means for
retaining the locking formation in the knife cut.
14. The interlock of claim 13 wherein said locking formation
retaining means comprises a notch formed on the locking formation
for bearing against the material comprising the top or bottom
member when the locking formation is inserted into the knife cut
therein.
15. The interlock of claim 13 wherein said locking formation
retaining means comprises a retaining tab formed when the locking
formation is inserted into the knife cut therein.
16. The interlock of claim 11 wherein both top and bottom members
are provided with a respective locking strap, the locking strap
integral with the top member being folded over the sidewall on one
side of the corner of the pallet and the locking strap integral
with the bottom member being folded over the sidewall of the other
side of the corner of the pallet.
17. A method of interlocking top and bottom substantially planar
members in nested relation comprising the steps of: folding a flap
formed on a substantially planar top member to a position
substantially perpendicular to the planar surface of the top
member; folding a flap formed on a substantially planar bottom
member to a position substantially perpendicular to the planar
surface of the bottom member, the flap on the top member forming a
sidewall and the flap on the bottom member forming an end wall when
the top and bottom members are in nested relation; folding a strap
extending from either the flap forming the sidewall or the flap
forming an end wall around the corner formed by the end wall and
sidewall; inserting the end of the strap into a slot formed in the
other of the sidewall or the end wall; and retaining the end of the
strap in the slot.
18. The method of claim 17 wherein the slot is provided with a
knife cut extending therefrom, the strap being driven through the
slot and knife cut by a mandrel that engages the strap.
19. The method of claim 18 wherein the strap is retained in the
slot by interaction of a tab formed on the end of the strap with
the corners formed by the knife cut and the slot.
20. The method of claim 18 additionally comprising deflecting the
corners formed by the knife cut and the slot in the direction in
which the strap is driven by the mandrel to facilitate insertion of
the strap into the slot.
21. Apparatus for assembling the top and bottom blanks of a
foldably-constructed pallet in nested relation comprising: an
intake for taking up and registering a top blank; an intake for
taking up and registering a bottom blank; clamps for folding the
registered top and bottom blanks to form support ribs therein; a
joiner for compressing the folded top and bottom blanks to each
other in nested relation to form the pallet; and a mandrel for
folding a strap formed on either of the top or bottom blank into
contact with the opposite blank and for inserting the end of the
strap into a cut formed in the material comprising the opposite
blank for interlocking the top and bottom blanks.
22. The apparatus of claim 21 additionally comprising a
programmable controller for regulating each of said top intake,
said bottom intake, said clamps, said joiner, and said mandrel.
23. The apparatus of claim 21 additionally comprising clamps for
folding said top and bottom blanks to form sidewalls, the strap
being folded into contact with the opposite blank at the corner
formed by adjacent sidewalls.
Description
[0001] This application claims the benefit of U.S. Provisional
Application Nos. 61/664,827, filed Jun. 27, 2012, and 61/665,358,
filed Jun. 28, 2012, which related applications are hereby
incorporated in their entirety into this application by this
specific reference thereto. This application is also a
continuation-in-part of co-pending application Ser. No. 13/134,092,
filed May 27, 2011, and a continuation-in-part of co-pending
application Ser. No. 13/134,508, filed Jun. 9, 2012, and both prior
co-pending applications are also hereby incorporated into this
application in their entirety by this specific reference
thereto.
[0002] The present invention relates generally to a force-resisting
structure or support and, more particularly, to a force-resisting
structure or support foldably constructed from one or more foldable
blanks and especially suited for use as a pallet or dunnage
support. In more detail, this invention pertains to pallets for
shipping goods, and more particularly to a corrugated paperboard
pallet that provides strong and stiff load support utilizing fully
recyclable corrugated, and a method of assembling a corrugated
paperboard pallet for use in shipping goods that reduces direct and
indirect shipping costs. The pallet of the present invention
reduces costs by utilizing only two flat paperboard blanks and by
requiring the minimum amount of material while being completely
machine-assembleable on-site at a shipping facility for rapid, high
volume use. The assembly method of the present invention reduces
waster material and facilitates just-in-time palletizing with
minimal labor, storage, transport, and uncertainty costs.
[0003] A pallet is primarily used to accommodate the mechanized
bulk handling and transport of products. A pallet typically
comprises a flat top surface for supporting a load, such as goods,
containers, or packages, a sufficient distance above the ground or
floor so that the fork of a forklift can be inserted under the top
surface in order to move the pallet with the entire load thereon
from place to place. Traditionally, most pallets have been made
from pieces of wood, specifically soft wood, assembled with metal
fasteners such as nails or screws. However, a number of problems
face present day users of conventional wooden pallets. The rising
cost of making and repairing wooden pallets has detracted from the
overall cost effectiveness of palletized shipments. Wooden pallets
are heavy, bulky and cumbersome, and empty wooden pallets require
substantial storage space. It is especially costly to transport
empty wooden pallets by rail or truck for reuse.
[0004] To save costs, conventional wooden pallets are returned to
the shipper for reuse, but since wooden pallets are heavy, bulky
and cumbersome, they are inconvenient to store and relatively
expensive to return to the shipper. If the wooden pallet is not
reused, it must be disposed of in a proper manner. Generally
speaking, landfill or other waste disposal sites will not accept
wooden pallets as is; rather, the pallets must first be reduced
either by chipping or burning prior to disposal. Chipping adds
significant cost to wooden pallet disposal, and burning wooden
pallets is often precluded by environmental regulations.
[0005] Some used wooden pallets are retrieved by pallet recyclers,
who usually accept only certain sizes of wooden pallets and
commonly charge a fee for their retrieval. After repair or
refurbishment, the recycler may attempt to resell the used wooden
pallets. The market for recycled wooden pallets is limited,
however, because many retailers refuse to receive goods transported
on recycled wooden pallets due to the lack of any standards
regulating the quality of the repair or refurbishment of used
wooden pallets. Products shipped internationally on even new wooden
pallets are faced with increasing regulations requiring various
forms of chemical treatment to the wood to prevent infestation and
transport of insects and parasites. Pallets constructed of plastic
or metal have been proposed, but plastic and metal pallets have
many of the same disadvantages as wooden pallets including being
heavy, bulky and cumbersome, being costly and inconvenient to
transport, store and dispose of, and being incompatible with
environmental preservation. In view of the various drawbacks to
pallets made from wood, plastic or metal, it would be desirable to
construct a pallet from a material other than wood, plastic or
metal, while maintaining many of the desirable characteristics
generally associated with pallets made from wood, plastic and metal
to provide a pallet that is lighter in weight, less expensive,
strong, of simplified construction, easier and less costly to
transport and store, that requires less space for storage, that is
more readily recyclable or disposable, and that minimizes
environmental impact.
[0006] Pallets made of corrugated paperboard have been proposed,
including pallets constructed from foldable corrugated paperboard
blanks as represented by U.S. Pat. No. 6,029,582 to Ogilvie, Jr. et
al. In many conventional corrugated paperboard pallets, the
vertical supports for the elevated top surface of the pallet are
secured with extraneous fasteners, including adhesive fasteners
such as glue or mechanical fasteners such as staples or clips, and
are not secured by the paperboard blanks themselves. Since an
individual pallet ordinarily includes a plurality of vertical
supports, the need to apply an extraneous fastener to each vertical
support adds to the cost, time, labor and complexity involved in
constructing or assembling the pallet. Furthermore, paperboard
pallets in which the vertical supports are secured with extraneous
fasteners are usually lacking in torsional strength. The extraneous
fasteners also introduce undesirable materials into the pallet, and
the fasteners may limit or complicate recyclability of the pallet.
Some paperboard pallets rely on frictional securement of a top
member of the pallet, which defines the elevated top surface, to a
bottom member of the pallet, and such frictional securements lend
little or no torsional support or strength to the overall pallet
structure. Many conventional paperboard pallets do not have full
perimeter support for the elevated top surface. Consequently, the
force from a load carried on the elevated top surface can cause the
elevated top surface to deflect in areas where the load is not
directly supported by vertical supports of the pallet. Some
conventional paperboard pallets cannot be foldably constructed or
assembled from a single paperboard blank but, rather, require at
least two foldable paperboard blanks that are assembled and then
fastened together with extraneous fasteners. Some paperboard
pallets attempt to duplicate the design of conventional wooden
pallets, and these pallets are usually both heavy and expensive
despite being made of paperboard.
[0007] For the many reasons of reducing costs, increasing
recyclability, lowering pallet weight, eliminating product
contamination, and reducing injuries, there is a desire to replace
conventional wooden pallets with corrugated pallets. There is also
a desire to have corrugated pallets that can be shipped flat and
then be completely machine- assembled on-site at a product shipper
to facilitate high volume, just-in-time supply and to reduce pallet
storage space and costs. To date, corrugated pallets have required
some or total hand assembly, making high volume use difficult, have
used excessive amounts of corrugated paperboard, making them
expensive, and have had less than sufficient strength and stiffness
for shipping many loads. Accordingly, an improved corrugated pallet
is needed that provides increased strength and stiffness for
widespread use in shipping, that makes minimal use of corrugated
for lower costs, and that can be completely machine-assembled for
rapid, high-volume product shipping applications.
[0008] Various objects, features and advantages of the present
invention will become apparent from the following description of
the preferred embodiments taken in conjunction with the
accompanying drawings wherein like reference numerals refer to like
or similar parts. Those skilled in the art will recognize, however,
that the embodiment(s) of the present invention that are described
and shown herein are only examples of specific embodiment(s), set
out for the purpose of describing the making and using of the
present invention, and that the embodiment(s) shown and/or
described herein are not the only embodiment(s) of a method and
apparatus constructed and/or performed in accordance with the
teachings of the present invention.
[0009] The present invention is an apparatus for assembling the top
and bottom blanks of a foldably-constructed pallet in nested
relation comprising an intake for taking up and registering a top
blank, an intake for taking up and registering a bottom blank,
clamps for folding the registered top and bottom blanks to form
support ribs therein; a joiner for compressing the folded top and
bottom blanks to each other in nested relation to form the pallet;
and a mandrel for folding a strap formed on either of the top or
bottom blank into contact with the opposite blank and for inserting
the end of the strap into a cut formed in the material comprising
the opposite blank for interlocking the top and bottom blanks.
[0010] The present invention is also a method for interlocking top
and bottom substantially planar members in nested relation
comprising the steps of folding a flap formed on a substantially
planar top member to a position substantially perpendicular to the
planar surface of the top member and folding a flap formed on a
substantially planar bottom member to a position substantially
perpendicular to the planar surface of the bottom member, the flap
on the top member forming a sidewall and the flap on the bottom
member forming an end wall when the top and bottom members are in
nested relation. A strap extending from either the flap forming the
sidewall or the flap forming an end wall is then folded around the
corner formed by the end wall and sidewall and the end of the strap
is inserted into a slot formed in the other of the sidewall or the
end wall and the end of the strap is retained in the slot.
[0011] In another aspect, a method of resisting torsional force
exerted on a force resisting structure comprised of top and bottom
substantially planar members, either or both of the top and bottom
planar members having folded portions forming sidewalls when and
assembled to each other in nested relation, comprising the steps of
folding a strap formed integrally with the top member into contact
with the bottom member and inserting a tab formed on the end of the
strap into a cut formed on the bottom member. A tab formed on the
end of the strap is then retained in the cut.
[0012] Referring to the figures,
[0013] FIG. 1 is a perspective view of a first embodiment of a
foldably-constructed, force-resisting corrugated paperboard pallet
that is constructed in accordance with the present invention.
[0014] FIG. 2 is a perspective view of the first, or top, and
second, bottom member of the foldably constructed force-resisting
structure of FIG. 1 prior to being foldably constructed into a
corrugated paperboard pallet in accordance with the method of the
present invention. FIG. 3 is a perspective view of the top surface
of the second, bottom member of the pallet of FIG. 1 prior to
assembly in accordance with the present invention.
[0015] FIG. 4 is a perspective view of the underside of the first,
top member of the foldably-constructed force-resisting corrugated
paperboard pallet of FIG. 1 prior to assembly in the assembly
method of the present invention.
[0016] FIG. 5 is a perspective view of the pallet bottom and pallet
top of the pallet of FIG. 1 aligned prior to compression together
in accordance with the assembly method of the present
invention.
[0017] FIG. 6 is a perspective view of the pallet bottom and pallet
top of the pallet of FIG. 1 after being compressed together in
accordance with the assembly method of the present invention.
[0018] FIG. 7 is a perspective view of the pallet of FIG. 1 after
the tuck flaps have been inserted into the corresponding cuts, or
slots, in accordance with the assembly method of the present
invention.
[0019] FIG. 8 is a perspective view of the pallet of FIG. 1 after
the jack passages are folded open in accordance with the assembly
method of the present invention.
[0020] FIG. 9 is a perspective, detailed view of one of the corners
of the foldably-constructed, force-resisting corrugated paperboard
pallet of FIG. 1 before a strap formed integrally with the sidewall
of the bottom member and comprising an interlocking element
constructed in accordance with the present invention is folded over
and inserted into a cut formed in the top member for retention
therein.
[0021] FIG. 10 is a perspective, detailed view similar to FIG. 10
showing the strap folded into contact with the top member.
[0022] FIG. 11 is a perspective, detailed view similar to FIG. 10
showing the strap after insertion of the tab formed on the end of
the strap into the cut formed in the top member.
[0023] FIG. 12 is a partial sectional view taken along the lines
12-12 in FIG. 1 showing the manner in which the tabs formed on the
end of the straps interact with the cut formed in the top and
bottom members.
[0024] FIG. 13 is a partial sectional view taken along the lines
13-13 in FIG. 1 showing the manner in which the tab formed on the
end of the strap integral with the sidewall of the bottom member
interacts with the margin of the cut formed in the top member.
[0025] FIG. 14 is a perspective view of the underside of the
force-resisting structure of FIG. 1.
[0026] FIG. 15 is a broken, perspective view of a second embodiment
of an interlocking arrangement for the peripheral side walls of the
force-resisting structure of the present invention.
[0027] FIGS. 16A-16D are perspective views similar to the views
shown in FIGS. 9-14 of the interlocking arrangement for the
peripheral side walls showing the steps of assembling the
interlock.
[0028] FIGS. 17A-17F are broken, perspective views of a third
embodiment of the interlocking arrangement for the peripheral side
walls of a force-resisting structure of the present invention
showing the steps of assembling the interlock.
[0029] FIG. 18 is a schematic diagram of a corrugated paperboard
pallet assembly machine for assembling corrugated pallets in
accordance with the method of the present invention.
[0030] FIG. 19 is a schematic diagram of a machine process for use
with the corrugated paperboard pallet assembly machine of FIG.
18.
[0031] Turning to the drawings, wherein like reference numerals
designate identical or corresponding parts, FIG. 1 shows a
corrugated paperboard pallet 30 in accordance with the present
invention. The pallet 30 has two sets of jack passages 31, 32 for
lifting and moving the pallet when loaded and is comprised of a
pallet bottom 50 and pallet top 70. The pallet of FIG. 1 prior to
assembly in flat blanks state is shown in FIG. 2 and is constructed
from the two flat sheets that form the pallet bottom 50 and pallet
top 70. Preferably, the sheet material from which blanks 50 and 70
are made is paperboard and, most preferably, corrugated paperboard.
However, thermal plastics or ductile metals could be used for the
sheet material. The blanks 50 and 70 can each be cut in any
suitable manner from the sheet material, such as by die or stamp
cutting, and can be treated in various ways to make them suitably
moisture and water resistant. Blanks 50 and 70 can be made from
virgin materials or from recycled materials and if made of
paperboard sheet material, are easily and routinely recyclable
while maintaining many of the desirable characteristics of less
readily recyclable materials such as wood, metal and various
plastics.
[0032] As explained further below, each blank 50, 70 has foldable
portions foldable along fold or crease lines defined or formed in
the blanks in order to foldably construct or assemble the top and
bottom members. Each blank 50, 70 is provided, where necessary,
with cut lines creating separable edges in the blanks for various
purposes including to define or form the foldable portions and/or
other structural elements, and/or to allow for or facilitate
folding of the foldable portions. The cut lines can be formed as
complete cuts extending entirely through the thickness of the sheet
material to form completely severed separable edges. Alternatively,
the cut lines can be formed as partial cuts, such as perforations
or score lines, extending partly through the thickness of the sheet
material comprising blanks 50, 70 to form partly severed, separable
edges that can be severed completely during foldable construction
or assembly. Either or both blanks 50, 70 may be provided with one
or more cut-out windows of various shapes and sizes where the sheet
material is partially removed or is completely removed during
foldable construction or assembly to serve various purposes. Some
of the purposes that may be served by the provision of cut-out
windows include simplifying the manufacture or preparation of the
blanks, facilitating foldable construction or assembly of the
force-resisting structure, allowing for interlocking engagement
between portions of the same or different blanks, and reducing
weight when possible without sacrificing structural strength. The
peripheral dimensions and thickness of the blanks 50, 70 and the
location of the fold lines, cut lines and cut-out windows can vary
in accordance with the features desired for the force-resisting
structure 30 based on its intended application.
[0033] The pallet bottom 50 of pallet 30 is shown in the assembly
process with ribs folded up in FIG. 3. The pallet bottom 50 is
folded in the manner described in the above-incorporated U.S.
application Ser. No. 13/134,092 to produce two parallel rib sets 51
near the midsection. Briefly, the parallel rib sets 51 comprise
edge ribs 52 located at each edge of the pallet bottom 50 having
horizontal notches 53 and middle ribs 54 located in the middle of
the pallet bottom having vertical notches 55. The pallet bottom 50
also comprises punch locks 56 in the parallel rib sets 51 for
locking them in place once folded. To allow for wheels of a pallet
jack to lift the pallet 30, cutouts 57 are provided in the pallet
bottom 50. Although as described above, other materials may be
used, in the embodiment shown, the pallet bottom 50 is constructed
of double wall B-C flute corrugated having a cross direction 90 and
machine direction 91 and the cross direction 90 is aligned such
that it becomes the vertical direction in the parallel rib sets 51
for high pallet strength and stiffness.
[0034] The pallet top 70 of pallet 30 is shown in the assembly
process with ribs folded down in FIG. 4. The pallet top 70 is
folded to produce two parallel rib sets 71 near the midsection,
also in the manner described in the above-incorporated U.S.
application Ser. No. 13/134,092. The parallel rib sets 71 comprise
edge ribs 72 located at each edge of the pallet top 70 having
horizontal notches 73 and middle ribs 74 located in the middle of
the pallet top having vertical notches 75. The pallet top 70 also
comprises punch locks 76 in the parallel rib sets 71 for locking
them in place once folded. The pallet top 70 is constructed of
double wall B-C flute corrugated having a cross direction 100 and
machine direction 101 and the cross direction 100 is aligned such
that it becomes the vertical direction in the parallel rib sets 71
for high pallet strength and stiffness.
[0035] After the rib sets 51, 71 re formed in both the pallet
bottom 50 and pallet top 70, the top and bottom 50, 70 are brought
together and aligned as shown in FIG. 5 (the process of aligning
the pallet top and bottom 50, 70 is described in more detail
below). The pallet bottom 50 is aligned perpendicular to the pallet
top 70 such that the rib sets 51, 71 intersect and such that the
vertical notches 55, 75 of the middle ribs 54, 74 are positioned
vertically intercepting each other as described in U.S. Ser. No.
13/134,092. The pallet is then assembled by compressing the pallet
bottom 50 and pallet top 70 together as shown in FIG. 6. The top of
the rib sets 51 of pallet bottom 50 rest on the underside of pallet
top 70 and the bottom of rib sets 71 of pallet top 70 rest on the
top side of pallet bottom 50.
[0036] After assembling the rib sets 51, 71 of the pallet bottom 50
and pallet top 70 together, the outer edge of the pallet 30 is
assembled. The assembly steps are set out in detail in Ser. No.
13/134092 and briefly shown in FIGS. 7-8, FIG. 7 showing insertion
of the tuck flaps. The outer edges of the pallet 30 are formed by
inserting bottom tuck flaps 80 into the edge notches 73 of pallet
top 70 and by inserting top tuck flaps 81 into the edge notches 53
of the pallet bottom 50. The corners of the pallet bottom 50 form
bottom locking straps 82 and the corners of the pallet top 70 form
top locking straps 83, both as described in more detail below. To
permit lifting of the pallet 30, passages for the forks of a pallet
jack (not shown) are opened as shown in FIG. 8. The folding of the
bottom tuck flaps 80 and top tuck flaps 81 creates pallet outer
sidewalls 86, 87. The outer sidewalls 86, 87 comprise flaps 84, 85
that are folded inwardly on each side of pallet 30 to create jack
passages 31, 32.
[0037] The pallet bottom 50 and pallet top 70 are then locked
together to provide a strong and reliable load carrying capability
with the completed pallet 30 as shown in FIG. 9. The interlocking
arrangement for the peripheral side walls of the force-resisting
structure constructed as shown in FIG. 1 is assembled by folding
bottom locking straps 82 over the top surface of pallet top 70 and
folding the top locking straps 83 under the bottom surface of
pallet bottom 40. After folding the straps 82, 83, the tabs 166
formed on the ends of straps 82, 83 are each inserted into
respective cuts 161, 261 in the pallet top 70 and pallet bottom 50
as shown in FIG. 1 to complete the locking and finish assembling
pallet 30.
[0038] To assemble the interlock, and as shown in more detail in
FIGS. 9-14, the ends of the locking straps 82, 83, which are
initially in the upright, or unfolded, position extending
perpendicularly to the flat surface of the top and bottom members
50, 70 as shown in FIGS. 7, 8, and 9, are folded into contact with
the flat surface of the corresponding top and bottom members 50,
70. In the next step in the method of assembling the interlock, the
tab 166 formed on the ends of the respective straps 82, 83 is
inserted into the corresponding cut 161, 261.
[0039] As best shown in FIG. 9, the cuts 161, 261, are formed in
the shape of a "C" with the closed side of the "C" closest to the
corner formed by the pallet sidewalls 86, 87. Referring to FIGS. 11
and 12, it can be seen that when the tab 166 on the end of the
respective strap 82, 83 is inserted into the cut 161, 261, a
portion of the material comprising the top and bottom members 50,
70 in which the cut 161, 261 is located is deflected downwardly, or
inwardly, forming a retaining tab 174. Retaining tab 174 bears
against the tab 166 to resist movement of the tab 166 in the
direction of the arrow 176 shown on FIG. 13 that would allow tab
166 to pull out of cut 161, 261, thereby effectively locking tab
166 in cut 161, 261. Note also that after tab 174 has been inserted
through the cut 161, 261, any attempt to pull tab 166 back out of
the cut 161, 261 causes the surfaces 180 formed by the notches 178
in the material comprising locking strap 82, 83 to engage the edges
of cut 161, 261, the surfaces 180 acting as stops to resist
movement of the tab 174 back out of cut 161, 261. As shown in FIGS.
8 and 9, both the top and bottom members 50, 70 of pallet 30 are
provided with straps 82, 83. As a result, and as best shown in FIG.
14, each of the corners formed by the sidewalls 86, 87 is "wrapped"
by straps 82, 83 that extend from the bottom member 70 up over top
member 50 and from top member 50 down under bottom member 70 on the
two sides formed by the sidewalls 86, 87 of each corner to provide
effective resistance to torsional forces on pallet 30, thereby
effectively increasing the load bearing capacity of pallet 30.
[0040] FIG. 15 illustrates a second embodiment of the locking
arrangement by which overlapping side walls of the top and bottom
members are interlocked. The locking arrangement is depicted in
FIG. 15 in conjunction with the overlapping side wall segments 937,
1037 at corners of the top member 912 and bottom member 913 as they
are assembled in nested relation to form the force-resisting
structure 910. The side wall segment 937A which meets or is
adjacent another side wall segment 937B at a corner of the top
member 912 is provided with a locking slot 961. The corresponding
side wall segment 1037A of bottom member 913 which meets or is
adjacent another side wall segment 1037B at a corner of bottom
member 913 is provided with a locking slot 1061 which is aligned
with the locking slot 961 when the top member 912 is assembled in
nested relation over the bottom member 913. A locking strap 963
formed from the top member blank and foldably connected to the end
of side wall segment 937B is folded around the corner of the
peripheral side wall of top member 912 and a locking tab 966 on
strap 963 is inserted into the aligned locking slots 961 and
1061.
[0041] As noted above, the interlocking arrangement of the present
invention is, in one embodiment, designed for automated assembly,
and the assembly steps are set out in sequence in FIGS. 16A-16B.
FIG. 16A is similar to FIG. 9 in that FIG. 16A shows the strap 82
extending from bottom member 50 after the top and bottom members
50, 70 have been assembled to each other as shown in FIG. 8, at
which point an "L"-shaped mandrel 168 is aligned with each of the
corners formed by sidewalls 86, 87 (only one corner being shown in
FIG. 16 for purposes of clarity). Mandrel 168 is then pivoted in
the direction of arrow B in FIG. 16A to the position shown in FIG.
16B, the "L"-shape of mandrel 168 causing the strap 82 to be folded
into contact with the top surface of top member 70. The pneumatic
cylinder 169 mounted to mandrel 168 is then activated (see below)
to extend piston 171 in the direction of arrow C as shown in FIG.
16C to punch, or insert, the tab 174 of strap 82 into the
"C"-shaped knife cut 161 in top member 70. As described above, the
"C"-shaped cut causes the material comprising top member 70 to
deflect downwardly along with the tab 166 on the distal end of
strap 82 to form the retainer tab 174 upon withdrawal of the piston
171 as shown in FIG. 16D. The end of piston 171 is provided with a
ball 173, the rounded surfaces of ball 173 facilitating insertion
and withdrawal from the cut 161 to punch the locking tab 166 and
retainer tab 174 through knife cut 161 and to leave the tabs 166,
174 in the cut 161 upon withdrawal of the ball 173.
[0042] A third embodiment of the locking arrangement, or corner
lock, is shown in FIG. 17, and like the embodiment shown in FIGS.
1-14, because the embodiment shown in FIG. 17 is adapted for
automated assembly of a force resisting structure constructed in
accordance with the method of the present invention, FIG. 17
appears as a series of steps FIG. 17A-17F for automated assembly of
the locking arrangement. Referring first to FIG. 17A, top member
1112 and bottom member 1113 are shown in nested relation, each of
top and bottom members 1112, 1113 being provided with flaps folded
substantially perpendicularly to form respective sidewalls 1136 and
1137 including side wall segments 1136A and 1137A that meet at a
corner of the respective top and bottom members 1112, 1113. To
provide increased resistance to torsional forces, a locking strap
1163 formed from the top member blank and foldably connected to the
end of side wall segment 1137B is folded around the corner of the
peripheral side wall of top member 1112 (FIG. 17B) and a locking
formation, or tab, 1166 on strap 1163 is inserted into the locking
slot 1161 as shown in FIG. 17F by action of the mandrel 1168 of a
device (not shown) for automated assembly of force resisting
structure 1110. Both top and bottom members 1112, 1113 are provided
with locking slots and the respective locking slots are aligned
when the top and bottom members are assembled to each other in
nested relation for insertion of the tab 1166 on strap 1163, but
only the locking slot 1161 formed in top member 1112 is visible in
FIG. 17.
[0043] As best shown in FIG. 17C, mandrel 1168 engages the outside
surface of locking strap 1163 as it moves in the direction
indicated by the arrow in FIG. 17C to drive the locking tab 1166 on
the end of strap 1163 through locking slot 1161 as shown in FIGS.
17D and 17E. The mandrel 1168 then reverses direction, leaving
locking tab 1166 in slot 1161 as it retreats.
[0044] As best shown in FIG. 17A, a knife cut 1170 through the
material comprising side wall segment 1136A of top member 1112
extends from one side of locking slot 1161, allowing the corners
1172 of the material comprising the side wall segment 1136A of top
member 1112 to deflect inwardly (in other words, to deflect in the
same direction as the arrow in FIG. 17C showing the direction of
movement of mandrel 1168) to facilitate insertion of tab 1166
through locking slot 1161 (for this reason, corners 1172 are also
referred to herein as flaps 1172). Those skilled in the art who
have the benefit of this disclosure will recognize that knife cut
1170 is not required for insertion of locking tab 1166 through
locking slot 1161, but being located at a point on wall segment
1136A that is aligned with mandrel 1168 when mandrel 1168 engages
locking strap 1163, the knife cut 1170 facilitates insertion of tab
1166 through locking slot 1161 for automated assembly of top and
bottom members 1112, 1113. Although the knife cut 1170 is shown in
FIG. 17 as extending from locking slot 1161 in a direction
approximately perpendicular to the long dimension of locking slot
1161 in the embodiment shown in FIG. 17, those skilled in the art
will recognize that knife cut 1170 need not be perpendicular to the
long dimension of locking slot 1161; the corners 1172 at the
intersection of locking slot 1161 and knife cut 1170 function as
flaps that deflect inwardly in the manner described herein even if
knife cut 1170 extends at an angle from locking slot 1161. It will
also be apparent from a review of the preferred embodiment shown in
FIG. 17 that locking slot 1161 is provided with knife cuts 1171
that extend in a direction parallel to the long dimension of the
locking slot. Although not required for the corner lock of the
present invention to function for its intended purpose of
interlocking the top and bottom members of a force resisting
structure as described herein, the parallel knife cuts 1171 do
cooperate with perpendicular knife cut 1170 and the mandrel 1168
that engages locking strap 1163 to facilitate passage of the
locking formation 1166 through locking slot 1161 for automated
assembly of the corner lock of the present invention as described
herein. Note also that, just as knife cut 1170 need not extend from
locking slot 1161 in a direction that is perpendicular to the long
dimension of locking slot 1161, it is not required that the knife
cut 1171 extend in a direction that is parallel to the long
dimension of locking slot 1161; the knife cut 1171 functions in the
manner described herein even if knife cuts 1171 extend at an angle
from locking slot 1161 and/or if only one end of locking slot 1161
is provided with a knife cut 1171.
[0045] It will be appreciated that, although described herein as
being located in the wall segment 1136A of the side wall 1136 of
top member 1112, wall segment 1137A of the side wall 1137 of bottom
member 1113 is likewise provided with a locking slot, knife cut(s),
and beveled flaps. However, because the structure in wall segment
1137A is not visible in the perspective view shown in FIG. 17
(because of the alignment of the respective slots, knife cuts, and
flaps), the description set out herein refers to wall segment
1136A. To further facilitate automated assembly of top member 1112
to bottom member 1113, the corners 1172 at the intersection of
locking slot 1161 and knife cut 1170 are angled, or beveled, by
relief cuts 1174. As a result of the beveled relief cuts 1174 of
flaps 1172 and the deflection of the flaps 1172 by mandrel 1168, a
hole 1176 is formed in the material comprising wall segment 1136A
and, as best shown in FIG. 17E, after driving tab 1166 through
locking slot 1161, mandrel 1168 extends through and is subsequently
withdrawn from that hole 1176.
[0046] The notches 1178 located near the distal end of locking
strap 1163 define the above-described locking formation 1166 and
serve at least two functions. First, notches 1178 are aligned with
the point at which mandrel 1168 engages the outside surface of
locking strap 1163, as well as the opening to locking slot 1161, to
provide a point of weakness along which the material comprising
locking strap 1163 deforms as the portion of locking strap 1163
comprised of locking formation 1166 is driven through the locking
slot 1161 past the deflecting flaps 1172, thereby allowing the
locking formation 1166 to be inserted through locking slot 1161.
Second, after locking formation 1166 has been driven through
locking slot 1161, top and bottom members 1112, 1113 are
interlocked in the sense that any attempt to pull locking formation
1166 back out of locking slot 1161 causes the surfaces 1180 formed
by the notches 1178 in the material comprising locking strap 1163
to engage the edges of locking slot 1161, the surfaces 1180 acting
as stops to resist movement of the locking formation 1166 back out
of locking slot 1163. As noted above, knife cuts 1171 are not
considered essential to the function of the interlocking fastening
element of the present invention, but if those cuts 1171 are
utilized, they provide an additional advantage such that the
preferred embodiment of the invention includes the cuts 1171.
Specifically, when a force is exerted on either the top or bottom
member 1112, 1113 that causes the two members to tend to separate
from each other such that locking formation 1166 is pulled in a
direction out of locking slot 1161, the stop surfaces 1180 engage
the back side of the material comprising the wall segments 1136
and/or 1137 near the knife cuts 1171. As a result of the engagement
of the stop surfaces 1180 and the material comprising the wall
segments 1136, 1137 near knife cuts 1171, the material comprising
wall segments 1136, 1137 deflects outwardly at knife cuts 1171,
thereby reducing the tendency of stop surfaces 1180 to wear and/or
deform. Over repeated cycles of the pulling of locking formation
1166 out of locking slot 1161, the deflection of the material
comprising wall segments 1136, 1137 at knife cuts 1171
substantially reduces the likelihood that the corners of stop
surfaces 1180 will be worn, deformed, or even sheared off, to the
point that they do not function to resist movement of locking
formation 1166 back out of locking slot 1163.
[0047] It should be appreciated that the locking arrangement can be
used to interlock various overlapping side walls of the top and
bottom members at the corners or at other locations along the side
walls (the interlocking fastening element of the present invention
is referred to herein as a "corner lock" only because it is located
at the corner of the preferred embodiment of a force resisting
structure, not because it must be located at a corner). It should
also be appreciated by those skilled in the art who have the
benefit of this disclosure that the insertion of a tab 166 (FIGS.
9-14) or locking formation 1166
[0048] (FIGS. 15 and 17) located on the end of a locking strap into
locking slot is but one way to provide resistance to torsional
force at the corners of the foldably-constructed force-resisting
member of the present invention. The same desirable resistance to
torsional (and other) forces can also be provided by a mechanical
fastener, such as stapling, at the corners of force resisting
structure 910, 1110, or by gluing or in other ways known in the
art. In another embodiment (not shown), a locking strap similar in
structure to strap 1163 located on a top or bottom member is not
provided with a locking formation; instead, the distal end of the
locking strap is passed through a locking slot and then secured to
the respective side wall segment of the other of the top or bottom
member by a mechanical fastener such as by stapling, gluing, or
other ways as known in the art. This alternative embodiment retains
an advantage of the force-resisting structures of the present
invention in that the top and bottom members are interlocked in
nested, assembled relation due to the interlocking relationship
between portions of the top and bottom members, i.e. the initial
blanks themselves.
[0049] Structural strength, rigidity and integrity, including
increased torsional strength and load support strength, are
enhanced because the portions of the top and bottom members that
interlock, secure or are secured to other portions, and/or provide
vertical support for the top member base panel, are formed from the
initial blanks of sheet material and remain integral with the
blanks. Structural strength, rigidity and integrity, including
torsional strength and load support strength, are also enhanced due
to the snug fit of the wings, the side wall flaps and/or the
vertical support ribs in the interior of the force-resisting
structures. The vertical support ribs form "X"-shaped or
cross-shaped vertical support structures within the force-resisting
structures for enhanced load support strength. The "X"-shaped or
cross-shaped vertical support structures are formed by interlocking
top and bottom support ribs or by support ribs provided in either
the top or bottom member. The force-resisting structures are
designed so that loads are supported along the lines of corrugation
of the sheet material for greater strength, rigidity and integrity,
including greater torsional strength and load support strength. The
side wall flaps and/or the wings are arranged to provide vertical
support entirely around the perimeter of the force-resisting
structures to resist deflection of the top member base panel. The
side portions of the top and bottom members include side walls,
with or without tuck flaps, and/or retention elements and the side
walls are either continuous or formed as side wall segments
separated by spaces. The side walls of the bottom members fit
interiorly of side walls of the top members when the top and bottom
members are in nested relation. Alternatively, the side walls of
the top members fit interiorly of the side walls of the bottom
members in nested relation. The side walls of the top and bottom
members are secured in overlapping relation and a locking
arrangement formed from the initial blank is used to secure
overlapping side walls, especially at the corners of the
force-resisting structures. The top and bottom members are easily
manufactured and shipped and/or stored in the unfolded condition in
which the top and bottom members occupy minimal space due to their
flat or planar configuration. The force-resisting structures are
disassembled or broken down for return to the unfolded condition
subsequent to use and are readily and easily recyclable or
disposable. Accordingly, the force-resisting structures minimize
adverse environmental impact, occupy minimal space prior to and/or
subsequent to assembly, and effectively save in production, storage
and transportation costs.
[0050] Referring now to FIG. 18, a schematic diagram of a
corrugated paperboard pallet assembly machine for use in assembling
the pallet 30 of FIG. 1 is shown. The pallet assembly machine 550
takes in top blanks 561 into a pallet top former 552 and takes in
bottom blanks 553 into the pallet bottom former 554. The top and
bottom joiner 555 assembles and folds together the pallet tops and
pallet bottoms to form finished pallets 556. The pallet assembly
machine 550 is operated by a control 557 that comprises a
controller 568 and solenoid valves 569. A compressor 560 feeds air
to the control 557 that operates the pallet top former 552, pallet
bottom former 554 and pallet top and bottom joiner 555. In one
embodiment, the pallet assembly machine 550 comprises open loop
pneumatic control for reliability and low costs. In the pallet top
former 552 is the initial step of registration 561 to insure proper
location and operation on the top blanks 551. In the pallet bottom
former 554 is the initial step of registration 563 to insure proper
location and operation on the pallet bottom blanks 553. In the top
and bottom joiner 555, the initial step is also registration
562.
[0051] A schematic diagram of a machine process for use with a
corrugated paperboard pallet production machine of FIG. 18 is shown
in FIG. 19. The process comprises three sections, the pallet top
former 580, pallet bottom former 581 and pallet top and bottom
joiner 582. The three sections 580, 581, 582 work together to form
a completed pallet. The pallet top former 580 comprises the steps
of picking up the top blank 583, taking in the top blank 584,
registering the location of the top blank 585, stopping motion of
the corrugated blank 586, clamping the top blank 587 and folding
the vertically extending members 588 on the top blank The pallet
bottom former comprises the steps of picking up the bottom blank
589, taking in the bottom blank 590, registering the location of
the bottom blank 581, stopping motion of the corrugated blank 592,
clamping the bottom blank 593 and folding the vertically extending
members 594 on the bottom blank The pallet top and bottom joiner
comprises the steps of taking in the pallet top and bottom 595,
registering the location of the pallet top and bottom 596, stopping
the motion of the corrugated pallet top and bottom 597, clamping
the pallet top and bottom together 598, and folding the pallet top
and bottom together 599. Pneumatic cylinders (see, for instance,
FIG. 16) are then activated at the command of controller 568 to
fold the flaps 84, 85 to create jack passages 32 at step 599A.
[0052] At step 599A, the top and bottom members 50, 70 appear as
shown in FIG. 8 and in the next two steps 599B and 599C, controller
568 activates another set of pneumatic cylinders to fold straps 82,
83 into contact with the respective top and bottom members 50, 70
as shown in FIG. 16 and then to insert the tabs 166 on the ends of
the straps into the respective cuts 161, 261 on top and bottom
members 50, 70. Folding of straps 82, 83 and insertion of the tabs
166 into cuts 161, 261 is accomplished by the "L"-shaped mandrel
168 (FIG. 16) in the directions of arrows B and C as shown in FIG.
16. After locking the tabs 166 in the respective cuts 161, 261, the
cycle is completed by ejecting the completed pallet to a palletizer
as at step 600. Of course those skilled in the art will recognize
that if the pallet assembly machine is being used to assemble a
pallet having an interlocking member as shown in FIG. 17, the tab
1166 is inserted into the knife cut, or slot 1170 by movement of
the mandrel 1168 in just a single direction (as shown by the arrow
in FIG. 17C) by activation of a pneumatic cylinder without
pivoting. After each pallet 30 is ejected, the pallet assembly
machine repeats the cycle 601 upon receipt of a signal from the
palletizer that another pallet is needed.
[0053] Those skilled in the art who have the benefit of this
disclosure will also recognize that certain changes can be made to
the component parts of the apparatus of the present invention
without changing the manner in which those parts function and/or
interact to achieve their intended result. For example, rather than
using the "L"-shaped mandrel 168 (FIG. 16) to fold the straps 82,
83 around the corners and into contact with the respective top and
bottom members 50, 70, the straps can be scored to form a point of
weakness that results in folds at the desired locations simply by
striking the back side of the straps with separate mandrels moving
in the directions of arrows B and C in FIG. 16. Similarly, it will
be recognized that the structure shown in FIG. 15 can be adapted
for automated assembly by, for instance, using an "L"-shaped
mandrel that pivots around the corner formed by sidewalls 937, 1037
with a pneumatic cylinder mounted thereto that drives the locking
formation, or tab, 966 on the end of strap 963 into the aligned
slots 961, 1061. All such changes, and the many others that will be
clear to those skilled in the art from this description of these
several embodiment(s) of the invention, are intended to fall within
the scope of the following, non-limiting claims.
* * * * *