Collapsible Pallet

The invention relates to a pallet, skid or spacer. More particularly, the invention relates to a pallet, skid or spacer constructed of bendable material which enables the pallet to assume an erected or collapsed position without disassembly.

Conventional pallets or spacers are used for supporting articles during storage or handling. The pallets must be constructed of a strong material to support the articles, yet be inexpensive and disposable. While wooden pallets have been used in the past, wooden pallets are relatively expensive, heavy and require a great deal of storage space when not in use.

Cardboard pallets and spacers are well known as a substitute for wood; see e.g., U.S. Pat. Nos. 2,728,545, 3,000,603, 3,115,105, 3,167,038, 3,952,672, and 4,563,377. These devices, however, are difficult to make with sufficient strength, and are either not collapsible or require disassembly before collapsing.

It is therefore an object of the present invention to provide a sturdy, light-weight pallet which is relatively inexpensive and easy to construct.

It is another object of the present invention to provide a pallet which is collapsible without disassembly of the pallet.

It is a further object of the invention to provide a pallet in which a plurality of pallet sections can be attached to form several configurations of pallets, each pallet being collapsible.

To achieve these and other objects and advantages, the present invention relates to a pallet which includes a symmetrical structure of two or more pallet sections, which enables the pallet section to assume an erected or collapsed position without disassembly. When the pallet sections are attached to form a symmetrical pallet structure, the pallet structure is collapsible into a V-shaped configuration.

These and other objects and advantages of the present invention will be appreciated from the following detailed description of the preferred embodiments, in which like elements bear like reference numerals, and wherein:

FIGS. 1a and 1b each illustrate a flat sheet of bendable material arranged to form a pallet section in accordance with the first and second embodiments of the present invention;

FIGS. 2a and 2b each illustrate a side view of the pallet section constructed from the sheets of FIGS. 1a and 1b, respectively;

FIGS. 3a and 3b each illustrate a side view of the pallets of FIGS. 2a and 2b in a collapsed condition, respectively;

FIG. 4 illustrates a flat sheet of bendable material arranged to form a pallet section in accordance with a third embodiment of the present invention;

FIG. 5 illustrates a side view of the pallet section constructed from the sheet of FIG. 4;

FIG. 6 illustrates the pallet of FIG. 5 in a collapsed condition;

FIG. 7 illustrates a flat sheet of bendable material arranged to form a pallet section in accordance with a fourth embodiment of the present invention;

FIG. 8 is a side view of the pallet section constructed from the sheet of FIG. 7;

FIG. 9 illustrates a side view of the pallet section of FIG. 8 in the collapsed condition;

FIG. 10 illustrates a perspective view of the pallet section of FIG. 8 having a series of aligned openings therein;

FIGS. 11A and 11B illustrate the erected and collapsed conditions of a two-part pallet structure formed by combining two pallet sections of FIG. 1A;

FIGS. 12A and 12B illustrate the erected and collapsed conditions of a two-part pallet structure formed by combining two pallet sections of FIG. 5;

FIGS. 13A and 13B illustrate the erected and collapsed conditions of a two-part pallet structure formed by combining two pallet sections of FIG. 8;

FIG. 13C illustrates the pallet structure of FIG. 13B with stiffeners;

FIGS. 14A and 14B illustrate the erected and collapsed conditions of a three part pallet structure formed by inserting a pallet component between two pallet sections of FIG. 2B; and

FIG. 15 illustrated a flat bendable sheet which is erected into the pallet component of FIGS. 14A and 14B.

FIG. 1a illustrates a length or single sheet 10 of cardboard or other bendable sheet-like material. The sheet 10 includes two opposite ends 12, 24, the end 12 being designated hereinafter as the first end. A plurality of fold lines 14, 16, 18, 20 and 22 are provided in the sheet parallel to the ends of the sheet, the pallet being constructed by folding the single sheet along the fold lines as discussed below. Preferably, the sheet is scored along the fold lines to facilitate folding, but such scoring is not necessary. A plurality of supports A-E are defined between adjacent pairs of fold lines 14-22 or a fold line and one of the ends 12, 24.

The pallet section of FIG. 2a is formed by folding the sheet of FIG. 1a into a channel-like structure with a rectangular cross-section. First and second supports A, B are formed by folding the sheet along the fold lines 22, 20 such that the first and second supports A, B are substantially parallel while a third support C (continguous with the first and second supports A, B) is perpendicular to the first and second support A, B. A fourth support D (continguous with the second support B) is formed parallel to the third support C by bending the fold line 18 so that the fourth support D is perpendicular to the first and second supports A, B. From this folding operation, a channel-like structure having a rectangular cross-section is formed with a fifth support E located inside the channel between the third and fourth supports C, D. The fifth support E has two portions, E1, E2. The first portion E1 between the fold lines 14, 16 is contiguous with the fourth support D. A second portion E2 is located between the fold line 14 and the first end 12, and has a length sufficient to extend from the fold line 14 to the fold line 20 in the erected configuration. In the erected configuration, the first portion E1 is substantially parallel to the first support A and includes an attachment portion X1 which is fixed to the first support A preferably by an adhesive, although other securing mechanisms such as staples are suitable. The second portion E2 extends obliquely with respect to the first and second supports A, B toward the fold line 20 between the second and third supports B, C.

The second portion E2 is unattached to any support. In the erected configuration, the second portion E2 provides stability to the pallet section since it functions as a cross-support for the channel-like structure by extending diagonally between the third and fourth supports C, D toward the corner formed by the fold line 20 between the second and third supports B, C. However, since the second portion E2 is unattached and the fold lines are flexible, the pallet section is collapsible to a substantially flat configuration illustrated in FIG. 3a. In the collapsed condition, the angles defined along the fold lines 16, 20 between the fourth and fifth supports D, E and between the second and third supports B, C, respectively, collapse to extend the angles defined along the fold lines 22, 18 between the first and third supports A, C and between the second and fourth supports B, D, respectively. The collapsing movement moves the second portion E2 with the end 12 to a position between the fold lines 20, 22 along the third support C. The erecting movement moves the second portion E2 with the first end 12 toward the fold line 20 where it stabilizes the pallet section.

In the embodiment of FIG. 2a, the end of the sheet opposite from the first edge 12 is the edge of the first support A. The opposite or second end of the sheet is designated with reference numeral 24 and is located adjacent the fifth support E in the erected condition. However, the length of the first support A may be increased as in FIG. 1b to form a second embodiment of the pallet section illustrated in FIG. 2b. The pallet section of FIG. 2b collapses in a manner similar to that of the pallet illustrated in FIG. 3a, as illustrated in FIG. 3b.

Other embodiments of pallet sections in accordance with the present invention are formed by adding additional support sections to the first support A of the second embodiment illustrated in FIG. 3a. In other words, the end 24 of the first support A is replaced with a fold line 24' and at least one additional section is added along the fold line 24'. For example, in a third embodiment illustrated in FIGS. 4-6, a sixth support F is defined between fold lines 24' and 26, and a seventh support G is defined between fold line 26 and the second end 28 of the sheet, so that the sixth support F is contiguous with the first support A and the seventh support G is contiguous with the sixth support F. In the erected configuration, the sixth support F is substantially perpendicular to the first and second supports A, B, and substantially parallel to the third and fourth supports C, D. In addition, in the erected condition, the seventh support G is substantially perpendicular to the third, fourth and sixth supports C, D, F, and substantially parallel to the first and second supports A, B.

In the third embodiment illustrated in FIGS. 4-6, an edge of the seventh support G is the second end 28 of the single sheet 10. Preferably, the second end 28 of the single sheet 10 is located adjacent the fold line 20 between the second and third supports B, C in the erected configuration, but this is unnecessary provided the seventh support G overlaps the second support B. In addition to the attachment portion X1 between the first portion E1 of the fifth support and the first support A, the third embodiment includes an attachment portion X2 for attaching the overlap between the seventh support G and the second support B.

The pallet of the third embodiment illustrated in FIG. 5 collapses in a manner similar to the first and second embodiments as illustrated in FIG. 6.

A fourth embodiment of the pallet section in accordance with the present invention is illustrated in FIGS. 7-9. The fourth embodiment is similar to the third embodiment except the length of the seventh support G is shortened to eliminate any overlap between the seventh support G and the third support C, and provide a fold line 28' from which two additional supports H, I are added to the seventh support G. As illustrated in FIG. 7, an eighth support H is contiguous to the seventh support G along fold line 28', while the ninth support I is contiguous with the eighth support H along the fold line 30. The ninth support I includes an edge which defines the second end 32 of the sheet 10.

In the erected configuration of the fourth embodiment, the eighth support H is substantially perpendicular to the first, second and seventh supports A, B, G, and substantially parallel to the third, fourth and sixth supports C, D, F. The eighth support H is located along side the fourth support D, and preferably fixed thereto by an attachment portion X3 located on either or both the fourth and/or eighth supports D, H.

The ninth support I is substantially parallel to the first, second and seventh supports A, B, G, and substantially perpendicular to the third, fourth, sixth and eight supports C, D, F, H. In addition to the attachment portion X1 between the first and fifth supports A, E1, the pallet section of the fourth embodiment includes an attachment portion X4 on the ninth support I for securing the ninth support to the first support A. Preferably, the second edge 32 of the ninth support I is adjacent to the fold line 24' between the first and sixth supports A, F.

The pallet section of the fourth embodiment collapses in a manner similar to the first, second and third embodiments, as illustrated in FIG. 9.

The supports of the pallet sections may include openings to facilitate handling of the pallets by a fork truck. For example, the fourth embodiment of the pallet section illustrated in FIG. 8 may include a series of aligned openings 50 in the third, fourth, fifth, sixth and eighth supports C, D, E2, F, H. Two series of aligned openings 50 may be provided for receiving each fork of the fork lift. Those skilled in the art recognize that other openings may be provided in a similar manner in all the embodiments described herein.

The pallet sections of the first through fourth embodiments may be combined to form a two part pallet structure. For example, the pallet section of FIG. 2a may be combined with another similar pallet section as illustrated in FIG. 11a to form a two-part symmetrical pallet structure with the fourth supports D abutting and the first support A being coplanar. The two pallet sections are fixed to one another by fixing together the fourth supports D of each pallet section, preferably by adhesive. The resulting pallet structure is collapsible into a V-shaped configuration as illustrated in FIG. 11b. In the collapsed configuration, the fourth supports D are located at the apex of the V-shaped configuration, the apex being the intersection area of the two pallet sections which define the legs of the V. In a similar manner, two pallet sections of the type illustrated in FIG. 5 can be combined to form a pallet as illustrated in FIG. 12a. With this construction, the sixth support of each pallet section are fixed together. Preferably, the first supports of each pallet section are coplanar to produce a symmetrical structure. The resulting symmetrical structure is collapsible into a substantially V-shaped configuration as illustrated in FIG. 12b with the sixth and first supports F, A forming the apex of the V-shaped configuration. An additional pallet can be constructed from the pallet section illustrated in FIG. 8 wherein two pallet sections are connected along the sixth support F as illustrated in FIG. 13a. The collapsed condition of the pallet illustrated in FIG. 13a is illustrated in FIG. 13b.

As discussed above in relation to FIG. 10, each pallet section of a symmetrical pallet structure may include a series of aligned openings to facilitate handling of the symmetrical pallet structure with a fork lift.

Further, additional vertical reinforcing supports or stiffeners may be provided on the pallet sections described herein to reinforce the pallet structure for greater strength, without interfering with the collapsing of the pallet. The stiffeners are separate from the single sheet of bendable material which forms the pallet section. For example, as illustrated in FIG. 13C, the pallet structure of FIG. 13B can be provided with a stiffener 55 at the junction of the two pallet sections (e.g., between the sixth supports F) and/or at the opposite unattached ends of the pallet sections (e.g., along the third supports C). The stiffeners 55 can be made of any material such as wood or cardboard and are fixed to the pallet sections, preferably by adhesive. The stiffeners 55 do not interfere with the collapsing of the pallet structure. In addition, the stiffener may be used with a single pallet section, or with a pallet structure of two or more pallet sections.

The present invention also contemplates the formation of a three piece collapsible pallet structure. In the three piece pallet structure, two of the pallet sections illustrated in FIG. 2b are combined such that the second ends 24 of each pallet section abut against each other as illustrated in FIG. 14a. With this construction, a space S is defined between the fourth supports D of each pallet section. A pallet component 10' can be located within the space between the fourth supports D of each pallet section. Preferably, the pallet component connects together the two pallet sections such that the pallet is collapsible into a V-shaped configuration illustrated in FIG. 14b. The pallet component 10' and the second edges 24 of each pallet section are located at the apex of the V-shaped configuration.

In the preferred embodiment, the pallet component includes a single sheet of bendable material with a plurality of fold lines defining a plurality of panels between adjacent pairs of fold lines. The sheet is folded into an erected configuration to define two rectangular channels RR, RL sharing a common panel, preferably a common base. In particular, the single sheet of bendable material for the pallet component 10' is illustrated in FIG. 15a and includes two ends 100, 200 and fold lines 110, 120, 130, 140, 150, 160, 170 and 180. A panel is located between each pair of fold lines and a fold line and an adjacent end. A first one RR of the rectangular channels includes: a first panel R.sub.1 between the end 100 and fold line 110; a second panel R.sub.2 perpendicular to the first panel R.sub.1 between the fold lines 110, 120; a third panel R.sub.3 perpendicular to the second panel R.sub.2 and parallel to the first panel R.sub.1 between the fold lines 120, 130; a fourth panel R.sub.4 parallel to the second panel between the fold lines 130, 140; and a fifth panel or common base R.sub.5 parallel to the first and third panels R.sub.1, R.sub.3 between the fold lines 140, 160. The second channel RL includes a sixth panel R.sub.6 between the fold lines 160, 170; a seventh panel R.sub.7 between the fold lines 170, 180; and an eighth panel R.sub.8 between the fold line 180 and end 200. In the preferred erected configuration, the first panel R.sub.1 is fixed to the common base or fifth panel R.sub.5 while the end 200 is unattached to the common base R.sub.5. Alternatively, the end 200 may be a fold line which defines an additional panel like the first panel R.sub.1, with both the first panel and additional panel being secured to the common base. Further, the common base or fifth panel R.sub.5 incudes a central fold line 150 aligned with the first ends 24 of the pallet sections such that the first and second rectangular channels RR, RL of the pallet component can collapse within the space S between the fourth supports of each pallet section. Other configurations of pallet components are possible provided the pallet component collapses into a V-shaped configurations and the apex of the V is located between the second ends of the pallet sections.

In all of the foregoing embodiments, the dimensions of the supports can be varied to increase or decrease the size of the pallet. In all of the embodiments, however, the third, fourth, sixth and eighth supports should have equal dimensions so that the width of the pallet section is constant. Further, the term pallet has been used herein, but those skilled in the art recognize the teachings herein are applicable to other supports such as skids or spacers.

The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification. The invention which is intended to be protected herein, however, is not to be construed as limited to the particular forms disclosed, since these are to be regarded as illustrative rather than restrictive. Variations and changes may be made by those skilled in the art without departing from the spirit of the invention.