Paper pallet

[0002] The present invention claims priority to U.S. Provisional Patent Application No. 60/155,048, filed Sep. 21, 1999, and entitled “Paper Pallet”. The identified provisional patent application is hereby incorporated by reference.

[0003] The present invention is related to pallets and, more specifically, pallets constructed of corrugated components that include a corrugated wrap, a corrugated topper and corrugated support blocks.

[0004] Paper pallets are gaining in popularity as they provide consumers with an easily recyclable option as compared to the standard wood pallets that have been used for years. However, paper pallets while desirably recyclable often bring other undesirable features. For instance, paper pallets often provide the user with a pallet of reduced strength as compared to a wood pallet of similar size and configuration. The reduced strength limits the load that the pallet may carry and additionally, allows for the damaging of the pallet itself under heavy loads. As such, there is a need in the art for a paper pallet that provides additional strength and stability, as well as easy assembly through the use of corrugated materials, e.g., a corrugated topper, corrugated support blocks, and a corrugated wrap.

[0005] The needs described above are in large measure met by the paper pallet of the present invention. The paper pallet generally comprises support blocks, a top pad, and a wrap. The support blocks are of a comb configuration, e.g., honeycomb or hexacomb. The top pad is of a corrugated material and is positioned above the support blocks. The wrap is also of a corrugated material and wraps, via direct contact, the top and side surfaces of the top pad as well as wrapping, via direct contact, at least two side surfaces of the support blocks.

[0006] The wrap may continue to wrap four sides of the six-sided support block so that the wrap is placed in a position intermediate the support block and top pad and, thereby, may be secured to the bottom surface of the top pad. Alternatively, the wrap may wrap to completely encompass the top pad and support blocks, i.e., in a shell configuration, such that the edges of the wrap join at a seam above the top pad. The wrap generally presents both an upper exterior surface and a lower exterior surface of the pallet; no additional platforms or pads are required above or below the wrap itself. The pallet may additionally include a second wrap for the wrapping of a central support block. This second wrap is secured to the bottom surface of the top pad when the second wrap is used.

[0007] A method for assembling the pallet generally includes the steps of: (1) presenting the wrap in a flat orientation; (2) securing the top pad to a central portion of the wrap; (3) securing one surface of the support blocks to a portion of the wrap proximate each side of the central portion, i.e., to each side of the top pad; (4) wrapping a second surface of each of the secured support blocks with the wrap; and (5) rolling each of the secured blocks to a position proximate the bottom surface of the secured top pad.

[0008] FIG. 1 provides a perspective view of a two-way paper pallet of the present invention.

[0009] FIG. 2 is an inside view of a wrap of the two-way paper pallet of FIG. 1.

[0010] FIG. 3 is an inside view of a top pad of the two-way paper pallet of FIG. 1.

[0011] FIG. 4 is a perspective view of a honeycomb block of the two-way paper pallet of FIG. 1.

[0012] FIG. 5 is an inside view of a runner of the two-way paper pallet of FIG. 1.

[0013] FIG. 6 is a perspective view of a four-way paper pallet of the present invention.

[0014] FIG. 7 is an inside view of a wrap of the four-way paper pallet of FIG. 6.

[0015] FIG. 8 is an inside view of a top pad of the four-way paper pallet of FIG. 6.

[0016] FIG. 9 is a perspective view of a honeycomb block of the four-way paper pallet of FIG. 6.

[0017] FIG. 10 is a perspective view of alternative embodiment of a two-way paper pallet.

[0018] FIG. 11 is an inside view of a wrap of the two-way paper pallet of FIG. 10.

[0019] FIG. 12 is a perspective view of a honeycomb block of the two-way paper pallet of FIG. 10.

[0020] A paper pallet 10 of the present invention may take a two-way configuration, see FIGS. 1-5, or, alternatively, a four-way configuration, see FIGS. 6-9. Each paper pallet 10, however, incorporates standard elements, i.e., a wrap 20, a top pad 22 and a plurality of support blocks 24.

[0021] Referring to FIGS. 1-5, the two-way configuration of paper pallet 10 preferably includes wrap 20, top pad 22, three support blocks 24, which comprise two side runners 26 and a central runner 28, and a central runner wrap 30.

[0022] Wrap 20, an inside view of which is depicted in FIG. 2, preferably comprises a sheet of single-wall corrugated having a kraft outer liner and a kraft inner liner separated by a corrugating medium incorporating a C-flute, i.e., 42 flutes per foot, and having a basis weight of 275 lbs./1000 ft². Wrap 20 is preferably of a rectangular configuration with the direction of corrugation along the elongate side of the rectangle. Of course, other types of corrugated, e.g., different basis weights, flute sizes and classifications, etc., may be used without departing from the spirit or scope of the invention. As shown in FIG. 2, the inside of each side of wrap 20 is preferably die-cut in four locations, as indicated by the dashed lines 32, to define a section-A 34, a section-B 36, a section-C 38, a section-D 40, and a central section 42. The die-cuts enable bending of section-A through section-D around side runners 26 (see FIG. 1).

[0023] Wrap 20 may be of any suitable size, however, by way of non-limiting example, the following dimensions have been found to be appropriate: (1) overall sheet—77{fraction (3/16)} by 48 inches; (2) section-A—5⅛ by 48 inches; (3) section-B—3{fraction (15/16)} by 48 inches; (4) section-C—5{fraction (3/16)} by 48 inches; (5) section-D—4{fraction (7/16)} by 48 inches; and (6) central section—39{fraction (13/16)} by 48 inches.

[0024] Top pad 22, an inside view of which is depicted in FIG. 3, preferably comprises a sheet of corrugated, e.g. tri-wall corrugated, having a kraft outer liner and a kraft inner liner, wherein the kraft liners are separated by a corrugating medium incorporating a combination ABC-flute. The corrugated preferably has a basis weight of 1100 lbs./1000 ft². The direction of corrugation of top pad 22 may be opposite to the direction of corrugation of wrap 20, to provide additional strength and stability to paper pallet 10. Of course other types of corrugated, e.g., double-wall corrugated, single-wall corrugated, different flute sizes and combinations, different basis weights, etc., may be used without departing from the spirit or scope of the invention. Additionally, a plurality of top pads 22 may be used in combination without departing from the spirit or scope of the invention. In cooperation with the dimensions provided above, by way of non-limiting example, the dimensions of 48 by 39⅝ inches have been found to be appropriate for top pad 22.

[0025] Support blocks 24, a perspective view of which is depicted in FIG. 4, are preferably of a paper honeycomb configuration and, more preferably, are HEXACOMB® blocks manufactured by Pactiv. The HEXACOMB® blocks preferably have a top kraft face 44, a bottom kraft face 45, and a type-3 core 46 separating the top and bottom faces. In cooperating with the dimensions provided above, by way of non-limiting example, the dimensions of 48 by 5 by 3¾ have been found to be appropriate for each of the three support blocks 24.

[0026] Central runner wrap 30, an inside of view of which is depicted in FIG. 5, preferably comprises a sheet of single-wall corrugated having a kraft outer liner and a kraft inner liner separated by a corrugating medium incorporating a C-flute. The sheet of corrugated preferably has a basis weight of 275 lbs./1000 ft². Central runner wrap 30 is preferably of a rectangular configuration with the direction of corrugation along the elongate side of the rectangle. Of course, other types of corrugated, e.g., different basis weights, flute sizes and combinations, etc., may be used without departing from the spirit or scope of the invention. As shown in FIG. 5, the inside central runner wrap 30 is preferably die-cut in four locations, as indicated by dashed lines 50, to define a section-E 52, a section-F 54, a section-G 56, a section-H 58, and a section-I 60. The die-cuts enable bending of section-E through section-I around central runner 28.

[0027] In cooperating with the dimensions provided above, by way of non-limiting example, the following dimensions for central runner wrap 30 have been found to be appropriate: (1) overall size—23⅞ by 48 inches; (2) section-E—5¼ by 48 inches; (3) section-F—4{fraction (3/16)} by 48 inches; (4) section-G—5{fraction (5/16)} by 48 inches; (5) section-H—4 by 48 inches; and (6) section-I—5⅛ by 48 inches.

[0028] In assembling the two-way configuration of paper pallet 10, a side runner assembly 62 is created with side runners 26, wrap 20 and top pad 22. To make side runner assembly 62, top kraft face 44 of side runners 26 are each preferably secured by adhesive to one of section-D 40 of wrap 20. Top pad 22 is preferably secured by adhesive to central section 42 of wrap 20. Each side runner 26 is then preferably rolled toward central section 42 such that one side of side runner 26 is covered by section-C 38, bottom kraft face 45 of side runner 26 is covered by section-B 36, and the second side of side runner 26 is covered by section-A 34. With respect to each side runner 26, the outside surface of section-A 34 is now in position immediately below top pad 22, i.e., top pad 22 and the outside of section-A 34 are substantially parallel, and is preferably secured by adhesive to top pad 22. Wrapping side runners 26 in this manner, wherein all sides of each side runner 26 are enclosed by wrap 20, and wrap 20 is secured, at least in part, to both the top and bottom surface of top pad 22, provides extra strength and stability to the two-way configuration of paper pallet 10 and helps to reduce the possibility that side runners 26 will separate from wrap 20 or that wrap 20 will separate from top pad 22.

[0029] Central runner 28 is preferably wrapped in central runner wrap 30 to create a central runner assembly 64. In achieving this objective, top kraft face 44 of central runner 28 is preferably secured by adhesive to section-G 56 of central runner wrap 30. Then, section-H 58 of central runner wrap 30 is folded up to cover a first side of central runner 28 and section-I 60 is folded to substantially cover the bottom kraft face central runner 28, where section-I 60 is preferably secured by adhesive. Section-F 54 of central runner wrap 30 is then folded up to cover a second side of central runner 28 and section-E 52 is folded to lay atop secured section-I 60. Section-E 52 is preferably secured by adhesive to secured section-I 60.

[0030] Central runner assembly 64 is preferably placed central to side runners 26 in side runner assembly 62, as shown in FIG. 1. In cooperating with the dimensions provided above, by way of non-limiting example, a space of approximately 12{fraction (7/16)} by 48 inches is provided on either side of central runner assembly 64, which allows for placement of forks for lifting.

[0031] Referring to FIGS. 6-9, the four-way configuration of paper pallet preferably includes wrap 20, top pad 22, and nine support blocks 24, which comprise six side runners 70 and three central runners 72.

[0032] Wrap 20, an inside view of which is depicted in FIG. 7, preferably comprises a sheet of single-wall corrugated having a kraft outer liner and a kraft inner liner separated by a corrugating medium incorporating a C-flute. The sheet of corrugated preferably has a basis weight of 275 lbs./1000 ft². Wrap 20 is preferably of a rectangular configuration with the direction of corrugation along the elongate side of the rectangle. Of course, other types of corrugated, e.g., different basis weights, flute sizes and combinations, etc., may be used without departing from the spirit or scope of the invention. As shown in FIG. 7, wrap 20 preferably includes four rectangular cut-outs 74. Further, the inside of each side of wrap 20 is preferably die-cut along two lines, as indicated by the dashed lines 76, to define a section-J 78, a section-K 80 and a central section 82. The die-cuts enable bending of section-J 78 and section-K 80 around side runners 70 (see FIG. 6).

[0033] Wrap 20 may be of any suitable size, however, by way of non-limiting example, the following dimensions have been found to be appropriate: (1) overall sheet—68⅞ by 44 inches; (2) section-J—15 by 44 inches; (3) section-K—3¾ by 44 inches; (4) central section—3⅜ by 44 inches; and (5) cut-outs—16¼ by 10 inches.

[0034] Top pad 22, an inside view of which is depicted in FIG. 8, preferably comprises a sheet of double-wall corrugated having a kraft outer liner and a kraft inner liner, wherein the kraft liners are separated by a corrugating medium incorporating a combination B/C flute. The double wall corrugated preferably has a basis weight of 350 pounds/1000 ft². The direction of corrugation of top pad 22 may be opposite to the direction of corrugation of wrap 20, to provide additional strength and stability to paper pallet 10. Of course, other types of corrugated, e.g., single-wall corrugated, tri-wall corrugated, different flute sizes and combinations, different basis weights, etc., may be used without departing from the spirit or scope of the invention. Additionally, a plurality of top pads 22 may be used in combination with each other without departing from the spirit or scope of the invention. In cooperation with the dimensions provided above, by way of non-limiting example, the dimensions of 30 by 44 inches for top pad 22 have been found to be appropriate.

[0035] Support blocks 24, a perspective view of which is depicted in FIG. 9, are preferably of a paper honeycomb configuration and, more preferably, are HEXACOMB® blocks manufactured by Pactiv. The HEXACOMB® blocks preferably have a top kraft face 84, a bottom kraft face 86 and a type-3 core 88 separating the top and bottom faces. In cooperating with the dimensions provided above, by way of non-limiting example, the dimensions of 8 by 5 by 3¾ inches have been found to be appropriate for each of the nine support blocks 24.

[0036] In assembling the four-way configuration of paper pallet 10, top kraft face 84 of three of side runners 70 are preferably secured by adhesive to a first side of central section 82 of wrap 20, with the side runner's elongate side proximate die-cut line 76 of section-K 80 and its short side proximate the edge of wrap 20 and/or the edge of cut-out 74. The three remaining side runners 70 are preferably placed similarly to the opposite side of wrap 20. Central runners 72 are preferably secured by adhesive to central section 82 of wrap 20 in a manner to be in substantial alignment with but intermediate to side runners 70. Top pad 22 is then preferably secured by adhesive to bottom face 86 of all support blocks 24, i.e., side runners 70 and central runners 72.

[0037] With top pad 22 secured, section-K 80 of wrap 20 is folded/bent to cover the elongate sides of all of side runners 70. Next, section-J 78 of wrap 20 is folded/bent to come over top pad 22 whereby section-J 78 of one side of wrap 20 meets section-J 78 of the other side of wrap 20 to create a seam 90 over the top face of top pad 90. Each of section-J 78 of wrap 20 is preferably secured to top pad 22 by adhesive to complete assembly of paper pallet 10. The four-way configuration of paper pallet may now raised and lowered by a forklift in the elongate direction of paper pallet 10 via openings 92, see FIG. 6, or in the shortened direction of paper pallet via openings 94.

[0038] Note that in the four-way configuration of paper pallet 10, because wrap 20 substantially encloses support blocks 24, i.e., side runners 70 and central runners 72, provides only a single seam 90 at the top of paper pallet 10, and because support blocks 24 are secured to both wrap 20 and top pad 22, extra strength and stability is provided to paper pallet 10. Further, these features help to reduce the possibility that support blocks 24 will separate from wrap 20 or top pad 22 during lifting.

[0039] It should be noted that top pad 22 may be eliminated from the two-way configuration or four-way configuration of paper pallet 10 if the load to be supported by paper pallet does not require the additional strength added by top pad 22.

[0040] Referring to FIGS. 10-12, an alternative embodiment of the two-way configuration of paper pallet 10 is shown and preferably includes wrap 20 and three support blocks 24, which comprise two side runners 26 and a central runner 28. While not depicted, top pad 22 may be incorporated as well.

[0041] Wrap 20, an inside view of which is depicted in FIG. 1, preferably comprises a sheet of single-wall corrugated having a kraft outer liner and a kraft inner liner separated by a corrugating medium incorporating a BC-flute and having a basis weight of 350 lbs./1000 ft². Wrap 20 is preferably of a rectangular configuration with the direction of corrugation along the elongate side of the rectangle. Of course, other types of corrugated, e.g., different basis weights, flute sizes and classifications, etc., may be used without departing from the spirit or scope of the invention. As shown in FIG. 11, the inside of each side of wrap 20 is preferably die-cut in two locations, as indicated by the dashed lines 32, a section-C 38, a section-D 40, and a central section 42. The die-cuts enable bending of section-C through section-D around side runners 26 (see FIG. 10).

[0042] Wrap 20 may be of any suitable size, however, by way of non-limiting example, the following dimensions have been found to be appropriate: (1) overall sheet—57{fraction (13/16)} by 48 inches; (2) section-C—5 by 48 inches; (5) section-D—4{fraction (1/16)} by 48 inches; and (6) central section—39{fraction (11/16)} by 48 inches.

[0043] Top pad 22, if used, is preferably similar to top pad 22 configuration of FIG. 3 and preferably comprises a sheet of tri-wall corrugated having a kraft outer liner and a kraft inner liner, wherein the kraft liners are separated by a corrugating medium incorporating a combination ABC-flute. The tri-wall corrugated preferably has a basis weight of 1100 lbs./1000 ft². The direction of corrugation of top pad 22 may be opposite to the direction of corrugation of wrap 20, to provide additional strength and stability to paper pallet 10. Of course other types of corrugated, e.g., double-wall corrugated, single-wall corrugated, different flute sizes and combinations, different basis weights, etc., may be used without departing from the spirit or scope of the invention. Additionally, a plurality of top pads 22 may be used in combination without departing from the spirit or scope of the invention.

[0044] Support blocks 24, a perspective view of which is depicted in FIG. 12, are preferably of a paper honeycomb configuration and, more preferably, are HEXACOMB® blocks manufactured by Pactiv. The HEXACOMB® blocks preferably have a top kraft face 44, a bottom kraft face 45, and a type-3 core 46 separating the top and bottom faces. In cooperating with the dimensions provided above, by way of non-limiting example, the dimensions of 48 by 5 by 3¾ have been found to be appropriate for each of the three support blocks 24.

[0045] In assembling the alternative embodiment of the two-way configuration of paper pallet 10, a side runner assembly 62 is created with side runners 26, wrap 20, and top pad 22 (if used). To make side runner assembly 62, top kraft face 44 of side runners 26 are each preferably secured by adhesive to one of section-C 38 of wrap 20. Top pad 22, if used, is preferably secured by adhesive to central section 42 of wrap 20. Each side runner 26 is then preferably rolled toward central section 42 such that one side of core 46 of side runner 26 is covered by section-D 40. Bottom kraft face 45 of side runner 46 may additionally be secured to central area 42, or to the bottom surface of top pad 22, if top pad 22 is used.

[0046] Central runner 28 is preferably secured by adhesive to central section 42, or to top pad 22, if used. Central runner 28 is preferably placed central to side runners 26 in side runner assembly 62, as shown in FIG. 10. In cooperating with the dimensions provided above, by way of non-limiting example, a space of approximately 12½ by 48 inches is provided on either side of central runner 28, which allows for placement of forks for lifting.

[0047] The present invention may be embodied in other specific forms without departing from the spirit of the essential attributes thereof; therefore, the illustrated embodiment should be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than the foregoing description to indicate the scope of the invention.