AU2010269108B2

AU2010269108B2 - Pallets made of plastics or paper

Info

Publication number: AU2010269108B2
Application number: AU2010269108A
Authority: AU
Inventors: Anirudh Jain; Vinod Kumar Jain
Original assignee: VINEX SINGAPORE Pte Ltd
Current assignee: VINEX SINGAPORE Pte Ltd
Priority date: 2010-04-19
Filing date: 2010-04-19
Publication date: 2011-07-07
Anticipated expiration: 2030-04-19
Also published as: WO2011003126A1

Abstract

There is disclosed a knockdown pallet system (10) typically of cardboard or plastic, for forming a pallet (12). The system includes a first pallet sheet (14) with primary flaps (20) joined at crease lines, and foldable to extend perpendicularly. A second pallet sheet (16) has apertures (30) for releasably locating the primary flaps so that the these flaps space the sheets apart in f4 a parallel relationship. One of the sheets serves as a base for the pallet while the other is for supporting a load. Some of the flaps of one of tle to extend through complementary apertures (44) he sheets have locking flaps (38) which are foldabin adjacent flaps of the other sheet, to lock the sheets together. The invention also includes foldable support sheets (80) for forming reinforcement structures, and a foldable pallet bin sheet (96) for forming a pallet bin with flaps for locking onto the pallet.

Description

WO 2011/003126 PCT/AU2010/000437 1 PALLETS MADE OF PLASTICS OR PAPER FIELD OF THE INVENTION This invention relates to pallets for supporting loads. In particular, it relates to a pallet system for forming pallets, and to a pallet and pallet and bin assembly made from such a system. BACKGROUND TO THE INVENTION Pallets for loading cargo have traditionally been made of wood, with wooden slats for supporting the loads. While these pallets have been sturdy, the wooden slats have not generally provided a smooth surface and this has been a source of potential damage to more fragile loads, and has given rise to some danger of injury to operators. In addition, wooden pallets are heavy and prone to insect infestation and fungus growth. Therefore, when such pallets have been loaded in containers, this has often necessitated fumigation of the containers. This gives rise to additional costs and wastage of time. It has also not been a suitable solution in relation to loads consisting of food items such as grains, and other items not suitable to be in a fumigated environment. In an attempt to solve problems relating to fumigation, heat treated wooden pallets have been used in place of simple wooden pallets. However, heat treated pallets are prone to absorb moisture, and during long transit periods, this itself can lead to fungus growth. Another problem often faced by those shipping such pallets is that the pallets have been constructed using nails, and these can damage the goods loaded on the pallets, and also be a potential cause of injury. A further disadvantage of wooden pallets is the fact that they involve the use of large amounts of wood and this causes difficulties and environmental problems in relation to disposal of the pallets.

WO 2011/003126 PCT/AU2010/000437 2 Pallets have also been made of plastics materials. These pallets are sturdy, relatively long-lasting and re-usable. However, they are generally bulky and costly. Because of the design of conventional plastic pallets, during prolonged usage, they tend to crack and break apart. Disposal of such broken plastic pallets is also environmentally disadvantageous. Various efforts have been made to develop paper pallets including cardboard pallets, which are easily recyclable. Paper pallets so far developed have used corrugated cardboard or honeycomb structures in order to provide the pallets with the required strength. As a result of these structures, these pallets involve the use of large amounts of paper. Accordingly, they tend to be bulky which is especially problematic and costly as these pallets, even when not being used for carrying loads, must be transported in an erected condition. While such pallets with honeycomb structures have been proven to take loads in excess of 1,000 kg, they are not economically viable. On the other hand, pallets made from corrugated cardboard, according to designs used thus far, have failed to make significant impact on the market due both to their cost and limited load-bearing capacity. Wooden pallets have therefore continued to be the preferred type of pallet due to their load-bearing capacity and cost, despite the above-mentioned disadvantages. It is an object of the present invention to overcome or ameliorate one or more of the disadvantages of the known pallets, or to provide a useful alternative thereto. SUMMARY OF THE INVENTION According to a first aspect of the invention there is provided a pallet system for forming a pallet, including: a substantially planar first pallet sheet having a first main portion and defining primary flaps, each primary flap being integrally joined to the first 3 1%" I ,j rL .AJ* JIa XJV--- ' Received 16 August 2010 main portion at a respective primary crease line, and being adapted to be folded into a folded position, relative to the first main portion, about the respective primary crease line, so as to extend substantially perpendicularly to the first main portion, a plurality of said primary flaps having locking edges; 5 and a substantially planar second pallet sheet having a second main portion and defining a plurality of second sheet apertures therein, each second sheet aperture being adapted to releasably receive and locate a said locking edge when the primary flap of which that locking edge forms a part is in its folded 10 position, whereby said primary flaps, when in their folded positions, and when said locking edges are so received in the respective second sheet apertures, space the first and second main portions apart from each other in a substantially parallel relationship in an erected condition of the pallet, wherein 15 one of the first and second main portions is adapted to serve as a base for the pallet for resting on a substrate while the other of the first and second main portions is adapted to support a load thereon, spaced above the substrate. In a preferred embodiment, each primary flap having a locking edge has an 20 edge portion at an opposite end of the primary flap to the first main portion, the locking edge protruding from the edge portion, and wherein the second sheet apertures are substantially complementary to the locking edges, such that, when the locking edges are received in said second sheet apertures, the edge portions abut the second main portion adjacent to the locking edges. 25 In a preferred embodiment, the second pallet sheet defines primary flaps, each primary flap of the second pallet sheet being integrally joined to the second main portion at a respective primary crease line, and being adapted to be folded into a folded position, relative to the second main portion, about the 30 respective primary crease line, so as to extend substantially perpendicularly to the second main portion. Preferably, at least one primary flap of one of the pallet sheets has a locking zone and defines, within that locking zone, a locking flap which is integrally Amended Sheet In30 A I AT WO 2011/003126 PCT/AU2010/000437 4 joined to that locking zone at a locking flap crease line, and which is adapted to be folded into a folded position, relative to that locking zone, about the respective locking flap crease line, so as to extend substantially perpendicularly to that locking zone, wherein at least one primary flap of the other pallet sheet has a locking zone and defines, within that locking zone, a locking aperture, and wherein, when a primary flap having a said locking flap and a primary flap having a said locking aperture are in their respective folded positions and the pallet is in said erected condition, these primary flaps are superposed over each other such that, when that locking flap is folded into its folded position, it extends though that locking aperture, thereby locating these primary flaps in relation to each other. Preferably each locking flap has opposite side edges which diverge from each other in a direction away from the respective locking flap crease line, and each locking aperture is complementarily shaped. In a preferred embodiment, a particular said primary flap of at least one of the pallet sheets has a primary region, and defines a secondary flap which is integrally joined to that primary region at a secondary crease line, and which is adapted to be folded into a folded position, relative to the primary region, about the secondary crease line, so as to extend substantially perpendicularly to the primary region, such that, when the particular primary flap is in its folded position relative to the main portion of the pallet sheet of which it forms a part, the secondary flap is also perpendicular to the main portion. Preferably the pallet sheet of which the secondary flap forms a part, defines, within the main portion of that sheet, at least one stop flap which is integrally joined to that main portion at a stop flap crease line, the stop flap being foldable into a folded position, relative to the main portion, about the stop flap crease line, so as to extend from the main portion, and wherein, when said particular primary flap is in its folded position relative to the main portion of that pallet sheet, and the secondary flap is in its folded position relative to the primary region of the primary flap, and the stop flap is WO 2011/003126 PCT/AU2010/000437 5 in its folded position relative to said main portion, the secondary flap abuts the stop flap whereby the stop flap prevents folding movement of the secondary flap in one rotational direction about the stop flap crease line. Preferably the other pallet sheet defines, within the main portion of that sheet, at least one further stop flap which is integrally joined to that main portion at a stop flap crease line, the further stop flap being foldable into a folded position, relative to that main portion, about the stop flap crease line, so as to extend from that main portion, and wherein, when the pallet is in said erected condition and said further stop flap is in its folded position relative to that main portion, the secondary flap abuts the further stop flap, whereby the further stop flap also prevents folding movement of the secondary flap in said one rotational direction about the stop flap crease line. Preferably said secondary flap is one secondary flap, and the particular primary flap defines another secondary flap which is integrally joined to the primary region of that primary flap at a secondary crease line, on an opposite side of the primary region to said one secondary flap. In a preferred embodiment, one of the primary flaps defined by one of the pallet sheets is a securement flap, that pallet sheet further defining a tertiary flap which is integrally joined to an opposite edge of the securement flap to the main portion of that pallet sheet, at a tertiary crease line, the tertiary flap being foldable relative to the securement flap about the tertiary crease line; wherein a primary flap of the other pallet sheet, when in its folded position, constitutes a lateral wall of that other pallet sheet, and the main portion of that other pallet sheet defines an access aperture adjacent to the lateral wall; and wherein, when the pallet is in said erected condition, the securement flap is adapted to be folded about its primary crease line so as to be superposed over one surface of the lateral wall, and the tertiary flap is adapted to be folded, about the tertiary crease line, so as to pass through the access aperture and to be superposed over an WO 2011/003126 PCT/AU2010/000437 6 opposite surface of the lateral wall with the lateral wall sandwiched between the securement and tertiary flaps. Preferably the tertiary flap has a locking edge portion, and the one of the pallet sheets which defines the securement flap further defines, in its main portion, a locating aperture adapted for locating the locking edge portion of the tertiary flap when that flap is superposed over said opposite surface of the lateral wall. In a preferred embodiment, the pallet system includes a support sheet adapted to be located between the first and second pallet sheets when the pallet is in said erected condition, the support sheet defining a base sheet portion and a side wall sheet portion integrally joined to one edge of the base sheet portion at a side wall crease line, and to be folded, into a folded position, about the side wall crease line relative to the base sheet portion, so as to extend substantially perpendicularly to the base sheet portion. Preferably the base sheet portion of the support sheet defines a support sheet aperture adapted such that, when the side wall sheet portion is folded into its folded position and the support sheet is disposed on the main portion of one of the pallet sheets, an edge portion of a primary flap of that pallet sheet can be received in the support sheet aperture, for locating the support sheet in relation to that pallet sheet. Preferably the primary flap the edge portion of which can be received in said support sheet aperture has a protrusion at said edge portion which protrudes from said aperture, and which is adapted to be received in a complementary aperture in the main portion of the other pallet sheet when the pallet is in said erected condition, for locating that other pallet sheet in relation to the support sheet. Preferably said side wall sheet portion has a protrusion at an edge thereof opposite the side which is joined to the base sheet portion, that protrusion being adapted such that, when the side wall sheet portion is folded into its WO 2011/003126 PCT/AU2010/000437 7 folded position and the support sheet is disposed on the main portion of said pallet sheet on which it is disposed, that protrusion can be received in a complementary aperture in that main portion for locating the support sheet relative to that one pallet sheet. Preferably the support sheet defines two said side wall sheet portions joined to opposite edges of the base sheet portion. Preferably, the pallet system includes two said support sheets. In a preferred embodiment, the pallet system further includes a pallet bin sheet for forming at least part of a pallet bin adapted to be located on the pallet in an assembled condition of the pallet and bin. Preferably the pallet bin sheet includes two pallet bin sheet portions integrally joined to each other at a bin sheet crease line. In a preferred embodiment, the pallet system further includes a pallet bin sheet for forming at least part of a pallet bin adapted to be located on the pallet in an assembled condition of the pallet and bin, wherein the pallet bin sheet includes two pallet bin sheet portions integrally joined to each other at a bin sheet crease line, wherein one of the pallet bin sheet portions defines at least one bin locking flap which is integrally joined to a remainder of that sheet portion at a crease line, and is foldable about that crease line relative to said remainder of that sheet portion into a folded position, wherein the securement flap defines at least one bin locking aperture complementary to said bin locking flap, and wherein the bin locking flap is adapted, when in its folded position, and when the pallet bin sheet and pallet are in the assembled condition, to extend through said bin locking aperture. Preferably the lateral wall flap defines at least one locking aperture complementary to said bin locking flap, and WO 2011/003126 PCT/AU2010/000437 8 the bin locking is adapted, when in its folded position, and when the pallet bin sheet and pallet are in the assembled condition, to extend through said locking aperture of the lateral wall. Preferably one of the pallet bin sheet portions defines at least one bin engagement flap which is integrally joined to a remainder of that sheet portion at a crease line, and is foldable about that crease line relative to said remainder of that sheet portion into a folded position, the bin engagement flap being adapted, when in its folded position, and when the pallet bin sheet and pallet are in the assembled condition, to extend through a space between two secondary flaps joined to two adjacent primary flaps. According to a second aspect of the invention there is provided a pallet formed from a pallet system according the first aspect of the invention or preferred embodiments thereof. According to a third aspect of the invention there is provided a pallet and pallet bin assembly formed from a pallet system according to the first aspect of the invention or preferred embodiments thereof. BRIEF DESCRIPTION OF THE DRAWINGS Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Figure 1 is a schematic perspective view of a pallet system for forming a pallet, the pallet system being represented as an exploded view of the pallet; Figure 2 is a schematic plan view of a pallet sheet forming part of the pallet system of Figure 1; Figure 3 is a schematic plan view of another pallet sheet forming part of the pallet system; WO 2011/003126 PCT/AU2010/000437 9 Figure 4 is a schematic plan view of a support sheet forming part of the pallet system; Figure 5 is an inverted schematic perspective view of the pallet sheet of Figure 2, with its flaps in a folded condition; Figure 6 is a schematic perspective view of the pallet sheet of Figure 3, with its flaps in a folded condition; Figure 7 is a schematic perspective view of the support sheet of Figure 4, in a folded condition; Figure 8 is an inverted schematic perspective view of the support sheet of Figure 7; Figure 9 is a schematic front view of a sheet for forming a pallet bin being part of the pallet system of Figure 1; Figure 10 is schematic perspective exploded view of a pallet according to the embodiment of Figure 1 and a pallet bin using the sheets of Figure 9; and Figure 11 is a schematic perspective view of the pallet and bin of Figure 10 in an assembled condition. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Referring to the drawings, there is shown a pallet system 10 for forming a pallet 12. The system 10 is shown as an exploded view of the pallet 12 in Figure 1, with the assembled pallet being shown in Figure 10. The pallet system 10 includes a planar first pallet sheet 14 and a planar second pallet sheet 16. The pallet sheets 14 and 16 are both of die-cut corrugated cardboard. As described below, the first pallet sheet 14 is to serve as a bottom component of the pallet 12, while the second pallet sheet 16 is to serve as a WO 2011/003126 PCT/AU2010/000437 10 top component of the pallet. Accordingly, these sheets are referred to below as a bottom pallet sheet 14 and a top pallet sheet 16, respectively. The bottom pallet sheet 14 has a main portion 18 and defines a number of primary flaps generally designated 20, but being specifically designated 20.1 to 20.22. Each primary flap 20 is integrally joined to the main portion 18 at a respective primary crease line 22, and is adapted to be folded into a folded position, relative to the main portion 18, about the respective crease line, so as to extend perpendicularly to that main portion as best seen in Figure 5. It will be seen that many of the primary flaps 20 have edge portions 24, with protrusions 26 extending from the edge portions. These protrusions 26 are referred to below as locking edges. The top pallet sheet 16 has a main portion 28 and defines a number of apertures therein, generally designated 30. Each aperture 30 is adapted to releasably receive and locate a locking edge 26 when the relevant flap portion 20 is in its folded position. For convenience, while each aperture is generally designated 30, it is specifically designated by a number having a suffix corresponding to that of the primary flap 20 whose locking edge 26 is received in that aperture. When the locking edges 26 are received in the apertures 30, the edge portions 24 of the relevant primary flaps 20 abut the main portion 28 of the top pallet sheet 16 adjacent to the locking edges. When the primary flaps 20 of the bottom pallet sheet 14 are in their folded positions, and when the locking edges 26 are received in the respective apertures 30, the primary flaps space the main portions 18 and 28 of the bottom and top sheets 14, 16 apart from each other in a parallel relationship. For convenience, this arrangement of the bottom and top sheets 14, 16 is referred to below as an erected condition of the pallet 12. The top pallet sheet 16 also defines primary flaps generally referenced 32, and specifically referenced 32.1 and 32.2. Each of these primary flaps 32 is WO 2011/003126 PCT/AU2010/000437 11 integrally joined to the main portion 28 of the top pallet sheet 16 at a respective crease line 34, and is adapted to be folded into a folded position, relative to that main portion, about the crease line, so as to extend substantially perpendicularly to that main portion as best seen in Figure 6. The primary flaps 32 of the top pallet sheet 16, have locking zones 36 and define, within those locking zones, locking flaps 38. The locking flaps 38 are integrally joined to the respective locking zones 36 at respective locking flap crease lines 40, and are adapted to be folded into folded positions, relative to the respective locking zones, about the crease lines, so as to extend perpendicularly to the locking zones. The corresponding primary flaps 20.1 to 20.6 of the bottom pallet sheet 14 also have locking zones 42, and define, within those locking zones, locking apertures 44 which are shaped complementarily to the locking flaps 38. When the primary flaps 32.1 of the top pallet sheet 16, which include the locking flaps 38, and the primary flaps 20.1 to 20.6 of the bottom pallet sheet 14 which include the locking apertures 44, are all in their folded positions, and the pallet 12 is in the erected condition, these primary flaps are superposed over each other. Thus, when the locking flaps 38 are folded into their folded positions, they extend though the corresponding locking apertures 44, thereby locating the superposed pairs of primary flaps in relation to each other, and hence locking the top and bottom pallet sheets 14, 16 to each other. It will be noted that each locking flap 38 has opposite side edges 46 which diverge from each other in a direction away from the locking flap crease lines 40, and the same applies to the locking apertures 44 which are complementarily shaped. This results in each locking flap having a neck portion 48, and each locking aperture having a collar portion 50. Thus, when the locking flaps 38 are folded so as to extend through the locking apertures 44, the neck portions 48 are held captive in the collar portions 50. This strengthens the locking effect of the locking flap- and locking aperture arrangement.

WO 2011/003126 PCT/AU2010/000437 12 The primary flaps 32.1 of the top pallet sheet 16, which flaps are referred to below as stabilised primary flaps, have primary regions 52, and define secondary flaps 54 which are integrally joined to the primary regions at crease lines 56. These secondary flaps 54 are adapted to be folded into a folded position, relative to the primary regions 52, about the crease lines 56, so as to extend perpendicularly to the primary regions as best seen in Figure 6. Thus, when each of these stabilised primary flaps 32.1 is in its folded position relative to the main portion 28 of the top pallet sheet 16, the secondary flaps 54 are also perpendicular to the main portion. The top pallet sheet 16 also defines, within its main portion 28, stop flaps 58 which are integrally joined to the main portion at crease lines 60. These stop flaps 58 are foldable into a folded positions, relative to the main portion 28, about the crease lines 60, so as to extend from the main portion. When the stabilised primary flaps 32.1 are in their folded positions as described above, with the secondary flaps 54 also in their folded positions relative to the primary regions 52 of the respective stabilised primary flaps, and the stop flaps 58 are also in their folded positions relative to said main portion 28 of the top pallet sheet 16, the secondary flaps abut the stop flaps. Thus, the stop flaps 58 limit folding movement of the secondary flaps 54 in the rotational directions indicated by the arrows 62 in Figure 6. The bottom pallet sheet 14 also defines, within its main portion 18, further stop flaps 64 which are integrally joined to that main portion at crease lines 66. These further stop flaps 64 are foldable into folded positions relative to that main portion 18, about the crease lines 66, so as to extend from that main portion. When the pallet 12 is in the erected condition and the further stop flaps 64 are in their folded positions, the secondary flaps 54 also abut the further stop flaps (in addition to abutting the stop flaps 58 of the top pallet sheet 16). Thus, the further stop flaps 64, in conjunction with the stops flaps 58, also limit movement of the secondary flaps 54 in the rotational directions 62.

WO 2011/003126 PCT/AU2010/000437 13 The primary flaps 32.2 of the top pallet sheet 16, referred to below as securement flaps, have tertiary flaps 68 integrally joined to them, at opposite edges to where those securement flaps are joined to the main portion 28 of the top pallet sheet. The tertiary flaps 68 are joined to the securement flaps 32 at crease lines 70, and are foldable relative to the securement flaps about these crease lines. The corresponding primary flaps 20.7 and 20.8 of the bottom pallet sheet 14, when in their folded positions, constitute lateral walls of the bottom pallet sheet, and are referred to as such, below. When the primary flaps 20.9 to 20.14 of the bottom pallet sheet 14, which are immediately adjacent to the lateral walls 20.7 and 20.8, are folded into their folded positions, the main portion 18 of the bottom pallet sheet defines access apertures 72 adjacent to those lateral walls, as best seen in Figure 5. When the pallet 12 is in the erected condition, the securement flaps 32.2 (being the flaps with the tertiary flaps 68 joined to them) can be folded about their crease lines 34 so as to be superposed over outer surfaces of the respective lateral walls 20.7 and 20.8 as indicated by the arrows 74 in Figure 6. Then (noting that the top pallet sheet is show in Figure 6 in an inverted position), the tertiary flaps 68 can be folded, about their crease lines 70, so as to pass through the access apertures 72 and to be superposed over the opposite, inner surfaces of the lateral walls 20.7 and 20.8, with the lateral walls being sandwiched between the securement flaps 32.2, and tertiary flaps 68. Each tertiary flap 68 has a locking edge portion 76, while the top pallet sheet 16 defines, in its main portion 28, locating apertures 78. These locating apertures 78 are adapted for locating the locking edge portions 76 when the tertiary flaps 68 are superposed over the inner surfaces of the lateral walls 20.7 and 20.8. In this manner, the securement flaps 32.2 and tertiary flaps 68 can effectively hold the lateral walls 20.7, 20.8 captive, thereby locking the bottom and top pallet sheets 14, 16 to each other.

WO 2011/003126 PCT/AU2010/000437 14 Also forming part of the pallet system 10 are two die-cut corrugated cardboard support sheets 80 (see especially Figure 4). Each support sheet 80 can optionally be located between the first and second pallet sheets 14 and 16 when the pallet 12 is in the erected condition. In particular, the support sheets 80 can be used when additional load bearing capacity of the pallet 12 is required. Each support sheet 80 has a base portion 82 and side wall portions 84. The side wall portions 84 are integrally joined to respective edges of the base sheet portion 82 at crease lines 86. The side wall portions 84 can be folded, into folded positions, about the crease lines 86 so as to extend perpendicularly to the base portion 82. The base portion 82 has apertures 88 therein. When lateral walls 20.7 and 20.8 of the bottom pallet sheet 14 are folded into their folded positions and the support sheet 80 is disposed on the main portion 18 of the bottom pallet sheet, the edge portions 24 of the primary flaps 20.15 to 20.22 of the bottom pallet sheet can be received in the apertures 88, for locating the support sheet in relation to the bottom pallet sheet. The protrusions 26 of those primary flaps 20.15 to 20.22 extend beyond the apertures 88. These protrusions 26 can be received in complementary apertures 30.15 to 30.22 in the main portion 28 of the top pallet sheet 16 when the pallet 12 is in the erected condition, and can thus locate the top pallet sheet in relation to the support sheet 80. Each side wall portion 84 of the support sheet 80 has a protrusion 90 at an edge opposite the side which is joined to the base portion 82. That protrusion 90 is adapted such that, when the side wall portions 84 are folded into their folded positions and the support sheets 80 are disposed on the main portion 18 of the bottom pallet sheet 14, the protrusions can be received in complementary apertures 92 in that main portion for locating the support sheets 80 relative to the bottom pallet sheet.

WO 2011/003126 PCT/AU2010/000437 15 When the pallet 12 is in an assembled condition as described further below, there are spaces between the successive pairs of adjacent secondary flaps 54 of the top pallet sheet 16, which are aligned with spaces between successive pairs of adjacent flaps 20.1 to 20.6 of the bottom pallet sheet 14. These aligned spaces are positioned so as to be suitable for receiving the tines of a fork lift, and are hence referred to below as fork lift ports 94 and are best seen in Figures 5, 6 and 10. In Figure 9 there is shown a pallet bin sheet 96. This sheet 96 is used together with another identical sheet to form a pallet bin 98 as shown in Figure 10. The pallet bin sheet 96 has a central crease line 100 which divides the sheet 96 into a first bin sheet portion 102 and a second bin sheet portion 104. The first bin sheet portion 102 has a pair of locking flaps 106 which are joined to a remainder of that sheet portion at crease lines 108 and are adapted to be folded about those crease lines. The second bin sheet portion 104 has a pair of engagement flaps 110 which are joined to a remainder of that sheet portion at crease lines 112, and are adapted to be folded about those crease lines. The pallet bin sheet 96, together with another identical sheet, is adapted to be secured to the pallet 12 as shown in Figures 10 and 11. The first and second sheet portions 102, 104 of the two sheets 96 are disposed adjacent to the outer surfaces of the flaps 32.2 and 52, respectively, of the top pallet sheet. The locking flaps 106 are then folded about the crease lines 108 into their folded positions so as to extend through aligned locking apertures 114 in the securement flaps 32.2, and aligned locking apertures 116 in the lateral walls 20.7 and 20.8 of the bottom pallet sheet 14. Similarly, the engagement flaps 110 are folded about the crease lines 112 into their folded positions, so as to extend into the fork lift ports 94. Thus, the locking flaps 106 and engagement flaps 110 secure the pallet bin sheets 96, and hence the pallet bin 98 as a whole, to the pallet 12. The manner of assembling the pallet 12 will now be described with reference to the drawings.

WO 2011/003126 PCT/AU2010/000437 16 As an initial step, the bottom pallet sheet 14 is placed on a substrate (not shown) and all of the flaps 20.1 to 20.22 are folded into their respective folded positions as shown in Figure 5. Then, each support sheet 80 is inverted and the flaps 84 are folded into their folded positions as shown in Figure 7. The support sheets 80 are then placed on the bottom pallet sheet 14 such that the edge portions 24 of the flaps 20.15 to 20.22 of the bottom pallet sheet extend into the apertures 88 of the support sheet. The protrusions 26 protrude through the apertures 88. Then the top pallet sheet 16 is inverted and all of its flaps other than the securement flaps 32.2 are folded into their respective folded positions as best seen in Figure 6. The top pallet sheet 16 is then turned right-way-up and placed over the bottom pallet sheet 14 to form the pallet 12 as shown in Figure 10. The top pallet sheet 16 is positioned so that the flaps 20.1 to 20.6 of the bottom pallet 14 sheet are within the bounds of the corresponding folded primary flaps 52 and secondary flaps 54 of the top pallet sheet. Similarly, the lateral wall flaps 20.7 and 20.8 of the bottom pallet sheet 14 are located within the bounds of the securement flaps 32.2 of the top pallet sheet 16. Thus, the securement flaps 32.2, when in their folded positions, are superposed over the outer surfaces of the lateral walls 20.7 and 20.8. With the top pallet sheet 16 engaged with the bottom pallet sheet 14 as described, the protrusions 26 of the flaps 20.15 to 20.22 of the bottom pallet sheet extend beyond the apertures 88 in the support sheets 80, into the corresponding apertures 30.15 to 30.22 of the top pallet sheet. Similarly, the protrusions 26 of the flaps 20.1 to 20.6, and 20.9 to 20.14 are received in the corresponding apertures 30.1 to 30.6, and 30.9 to 30.14.

WO 2011/003126 PCT/AU2010/000437 17 The stop flaps 58 and 64 are also folded into their folded positions to limit movement of the corresponding secondary flaps 54. Finally, the locking flaps 38 are folded to extend through the locking apertures 44 as described above. The pallet 12 is then inverted. The tertiary flaps 68 are then folded around the free edges of the lateral walls 20.7 and 20.8, and moved so that the locking edge portions 76 of the tertiary flaps snap into the locating apertures 78 of the top pallet sheet 16. The assembled pallet 12 is then again turned right-way-up so that the upper surface of the main portion 28 of the top pallet sheet 16 serves as an upward facing pallet deck on which a load can be supported. If it is desired to use the pallet bin 98, two pallet bin sheets 96 are folded into their folded conditions to form the bin, and are placed over the pallet 12 so that the portions 102 and 104 of the bin sheet extend around the pallet as shown in Figure 11. In this position of the bin sheet 96, its engagement flaps 110 are aligned with the fork lift ports 94. The engagement flaps 110 are folded into the fork lift ports 94, and the locking tabs 106 are folded so as to extend into the locking tab apertures 114 in the securement flaps 32.2, thus completing the assembly of the pallet 12 and pallet bin 98. It will be appreciated by those skilled in the art that other suitable sequences of erecting the pallet 12 may be used instead. While the pallet 12 can be erected as described above without the aid of any bonding means in addition to the interlocking of the various flaps and apertures, if additional strength is required, a suitable glue can be applied, for example with a hot-melt glue gun, to seal and secure the locking flaps.

WO 2011/003126 PCT/AU2010/000437 18 However, importantly, it will be appreciated by those skilled in the art that where glue or the like is not used, the pallet system 10, pallet 12 and bin 98 are of a knockdown type. Although this invention has been described above in relation to corrugated cardboard materials, it can alternatively involve the use of plastic materials for the various components. Embodiments of the invention have various advantages, as set out below. e The upper surface of the main portion 28 of the top pallet sheet 16 provides for a clear, flat pallet deck. This facilitates palletization of goods and assists in avoiding damage to the bottom of goods on the pallet. e The pallet 12 can provide a simple-to-use, efficient, effective and economically viable alternative to wooden pallets and other existing pallets. e The spaces created when the flaps 20.15 to 20.22 are folded into their folded positions enables the wheels of a Pallet Lift, that is positioned between the top and bottom pallet sheets 16, 14, to rest on the substrate on which the pallet 12 is supported, while lifting the pallet. e The surfaces of various components of the pallet 12 can be suitably treated to render them water resistant and grease proof. e The pallet 12 is suited to being manufactured from sheets of corrugated cardboard which are of straightforward design, which are easy to manufacture, which use relatively small amounts of paper, and which involve relatively small amounts of wastage of paper and cardboard. e The pallet 12 is also suited to being manufactured from plastic sheets embodiments of which may be suitable for use in refrigerated and humid conditions. - Such pallets using plastics material use relatively small amounts of plastic, which may be re-usable, and this can assist in minimising any detriment to the environment, especially when compared with conventional plastic pallets.

WO 2011/003126 PCT/AU2010/000437 19 e The design of the pallet system facilitates easy transport, storage and assembly while also providing for a stable pallet. e The nature of the pallet system 10 is such that the need for fumigation of transport containers containing such pallets can be minimised or even avoided. e The interlocking nature of the various flaps and apertures is such that the pallet 12 can remain stably assembled while supporting both static and dynamic loads. e The design of the pallet bin sheets 96 is such that the pallet bins 98, which are relatively large when compared with existing bins, can be easily attached to the pallet 12, and can assist in avoiding the need for glues, staples or other jointing materials or methods. e The dimensions of the pallet 12 can be specified according to a user's requirements and can be based on the desired load bearing capabilities. For example, the following parameters of the pallets may be specified according the user's requirements: e The paper weight of the cardboard sheets, for example specified in grams per square metre; e The paper strength, for example specified as bursting strength and rupture strength; e The corrugation type, for example a combination of A, B and C flutes; e The position of the support sheets 80; e The treatment of the pallet surface, for example with functional coatings during the process of corrugation, for rendering the pallet water proof or grease resistant; e For cardboard pallets, the use of specific glues for assisting the pallet to withstand loads under humid conditions; e In the case of plastic pallets the load bearing capacities can be varied using different plastic materials and varying the thickness of the plastic sheets used.

WO 2011/003126 PCT/AU2010/000437 20 Although the invention is described above in relation to preferred embodiments, it will be appreciated by those skilled in the art that it is not limited to those embodiments, but may be embodied in many other forms.

Claims

1. A pallet system for forming a pallet, including: a substantially planar first pallet sheet having a first main portion and 5 defining primary flaps, each primary flap being integrally joined to the first main portion at a respective primary crease line, and being adapted to be folded into a folded position, relative to the first main portion, about the respective primary crease line, so as to extend substantially perpendicularly to the first main portion, a plurality of said primary flaps having locking edges; 10 and a substantially planar second pallet sheet having a second main portion and defining a plurality of second sheet apertures therein, each second sheet aperture being adapted to releasably receive and locate a said locking edge when the primary flap of which that locking edge forms a part is in its folded 15 position, whereby said primary flaps, when in their folded positions, and when said locking edges are so received in the respective second sheet apertures, space the first and second main portions apart from each other in a substantially parallel relationship in an erected condition of the pallet, wherein 20 one of the first and second main portions is adapted to serve as a base for the pallet for resting on a substrate while the other of the first and second main portions is adapted to support a load thereon, spaced above the substrate.

2. A pallet system for forming a pallet, as claimed in claim 1, wherein each 25 primary flap having a locking edge has an edge portion at an opposite end of the primary flap to the first main portion, the locking edge protruding from the edge portion, and wherein the second sheet apertures are substantially complementary to the locking edges, such that, when the locking edges are received in said second sheet apertures, the edge portions abut the second 30 main portion adjacent to the locking edges.

3. A pallet system for forming a pallet, as claimed in claim 1 or claim 2, wherein the second pallet sheet defines primary flaps, each primary flap of the second pallet sheet being integrally joined to the second main portion at a Amended Sheet IDQA /A TT Received 16 August 2010 respective primary crease line, and being adapted to be folded into a folded * position, relative to the second main portion, about the respective primary crease line, so as to extend substantially perpendicularly to the second main portion. 5

4. A pallet system for forming a pallet, as claimed in claim 3, wherein at least one primary flap of one of the pallet sheets has a locking zone and defines, within that locking zone, a locking flap which is integrally joined to that locking zone at a locking flap crease line, and which is adapted 10 to be folded into a folded position, relative to that locking zone, about the respective locking flap crease line, so as to extend substantially perpendicularly to that locking zone, wherein at least one primary flap of the other pallet sheet has a locking zone and defines, within that locking zone, a locking aperture, and 15 wherein, when a primary flap having a said locking flap and a primary flap having a said locking aperture are in their respective folded positions and the pallet is in said erected condition, these primary flaps are superposed over each other such that, when that locking flap is folded into its folded position, it extends though that locking aperture, thereby locating these primary flaps in 20 relation to each other.

5. A pallet system for forming a pallet, as claimed in claim 4, wherein each locking flap has opposite side edges which diverge from each other in a direction away from the respective locking flap crease line, and each locking 25 aperture is complementarily shaped.

6. A pallet system for forming a pallet, as claimed in any one of claims 3 to 5, wherein a particular said primary flap of at least one of the pallet sheets has a primary region, and defines a secondary flap which is integrally joined to 30 that primary region at a secondary crease line, and which is adapted to be folded into a folded position, relative to the primary region, about the secondary crease line, so as to extend substantially perpendicularly to the primary region, such that, when the particular primary flap is in its folded Amended Sheet IPEA/AU 23 Received 16 August 2010 position relative to the main portion of the pallet sheet of which it forms a part, * the secondary flap is also perpendicular to the main portion.

7. A pallet system for forming a pallet, as claimed in claim 6, 5 wherein the pallet sheet of which the secondary flap forms a part, defines, within the main portion of that sheet, at least one stop flap which is integrally joined to that main portion at a stop flap crease line, the stop flap being foldable into a folded position, relative to the main portion, about the stop flap crease line, so as to extend from the main portion, and 10 wherein, when said particular primary flap is in its folded position relative to the main portion of that pallet sheet, and the secondary flap is in its folded position relative to the primary region of the primary flap, and the stop flap is in its folded position relative to said main portion, the secondary flap abuts the stop flap whereby the stop flap prevents folding movement of the secondary 15 flap in one rotational direction about the stop flap crease line.

8. A pallet system for forming a pallet, as claimed in claim 7, wherein the other pallet sheet defines, within the main portion of that sheet, at least one further stop flap which is integrally joined to that main 20 portion at a stop flap crease line, the further stop flap being foldable into a folded position, relative to that main portion, about the stop flap crease line, so as to extend from that main portion, and wherein, when the pallet is in said erected condition and said further stop flap is in its folded position relative to that main portion, the secondary flap 25 abuts the further stop flap, whereby the further stop flap also prevents folding movement of the secondary flap in said one rotational direction about the stop flap crease line.

9. A pallet system for forming a pallet, as claimed in any one of claims 6, 7 30 and 8, wherein said secondary flap is one secondary flap, and the particular primary flap defines another secondary flap which is integrally joined to the primary region of that primary flap at a secondary crease line, on an opposite side of the primary region to said one secondary flap. Amended Sheet MTV A / A I T Received 16 August 2010

10. A pallet system for forming a pallet, as claimed in any one of claims 3 to 9, wherein one of the primary flaps defined by one of the pallet sheets is a securement flap, that pallet sheet further defining a tertiary flap which is 5 integrally joined to an opposite edge of the securement flap to the main portion of that pallet sheet, at a tertiary crease line, the tertiary flap being foldable relative to the securement flap about the tertiary crease line; wherein a primary flap of the other pallet sheet, when in its folded position, constitutes a lateral wall of that other pallet sheet, and the main 10 portion of that other pallet sheet defines an access aperture adjacent to the lateral wall; and wherein, when the pallet is in said erected condition, the securement flap is adapted to be folded about its primary crease line so as to be superposed over one surface of the lateral wall, 15 and the tertiary flap is adapted to be folded, about the tertiary crease line, so as to pass through the access aperture and to be superposed over an opposite surface of the lateral wall with the lateral wall sandwiched between the securement and tertiary flaps. 20

11. A pallet system for forming a pallet, as claimed in claim 10, wherein the tertiary flap has a locking edge portion, and wherein the one of the pallet sheets which defines the securement flap further defines, in its main portion, a locating aperture adapted for locating the locking edge portion of the tertiary flap when that flap is superposed over said opposite surface of the lateral wall. 25

12. A pallet system for forming a pallet, as claimed in any one of the preceding claims, including a support sheet adapted to be located between the first and second pallet sheets when the pallet is in said erected condition, the support sheet defining a base sheet portion and a side wall sheet portion 30 integrally joined to one edge of the base sheet portion at a side wall crease line, and to be folded, into a folded position, about the side wall crease line relative to the base sheet portion, so as to extend substantially perpendicularly to the base sheet portion. Amended Sheet IPEA/AU 25 1 % I rI U I UVtJ / Received 16 August 2010

13. A pallet system for forming a pallet, as claimed in claim 12, wherein the base sheet portion of the support sheet defines a support sheet aperture adapted such that, when the side wall sheet portion is folded into its folded position and the support sheet is disposed on the main portion of one of the 5 pallet sheets, an edge portion of a primary flap of that pallet sheet can be received in the support sheet aperture, for locating the support sheet in relation to that pallet sheet.

14. A pallet system for forming a pallet, as claimed in claim 13, wherein the 10 primary flap the edge portion of which can be received in said support sheet aperture has a protrusion at said edge portion which protrudes from said aperture, and which is adapted to be received in a complementary aperture in the main portion of the other pallet sheet when the pallet is in said erected condition, for locating that other pallet sheet in relation to the support sheet. 15

15. A pallet system for forming a pallet, as claimed in any one of claims 12 to 14, wherein said side wall sheet portion has a protrusion at an edge thereof opposite the side which is joined to the base sheet portion, that protrusion being adapted such that, when the side wall sheet portion is folded into its 20 folded position and the support sheet is disposed on the main portion of said pallet sheet on which it is disposed, that protrusion can be received in a complementary aperture in that main portion for locating the support sheet relative to that one pallet sheet. 25

16. A pallet system for forming a pallet, as claimed in any one of claims 12 to 15, wherein the support sheet defines two said side wall sheet portions joined to opposite edges of the base sheet portion.

17. A pallet system for forming a pallet, as claimed in any one of claims 12 to 30 16, including two said support sheets.

18. A pallet system for forming a pallet, as claimed in any one of the preceding claims, further including a pallet bin sheet for forming at least part Amended Sheet IPEA/AU 26 Received 16 August 2010 of a pallet bin adapted to be located on the pallet in an assembled condition of the pallet and bin.

19. A pallet system for forming a pallet, as claimed in claim 18 wherein the 5 pallet bin sheet includes two pallet bin sheet portions integrally joined to each other at a bin sheet crease line.

20. A pallet system for forming a pallet, as claimed in claim 10, further including a pallet bin sheet for forming at least part of a pallet bin 10 adapted to be located on the pallet in an assembled condition of the pallet and bin, wherein the pallet bin sheet includes two pallet bin sheet portions integrally joined to each other at a bin sheet crease line, wherein one of the pallet bin sheet portions defines at least one bin 15 locking flap which is integrally joined to a remainder of that sheet portion at a crease line, and is foldable about that crease line relative to said remainder of that sheet portion into a folded position, wherein the securement flap defines at least one bin locking -aperture complementary to said bin locking flap, and 20 wherein the bin locking flap is adapted, when in its folded position, and when the pallet bin sheet and pallet are in the assembled condition, to extend through said bin locking aperture.

21. A pallet system for forming a pallet, as claimed in claim 20, 25 wherein the lateral wall flap defines at least one locking aperture complementary to said bin locking flap, and wherein the bin locking is adapted, when in its folded position, and when the pallet bin sheet and pallet are in the assembled condition, to extend through said locking aperture of the lateral wall. 30

22. A pallet system for forming a pallet, as claimed in claim 20, wherein one of the pallet bin sheet portions defines at least one bin engagement flap which is integrally joined to a remainder of that sheet portion at a crease line, and is foldable about that crease line relative to said Amended Sheet IPEA/AU 27 Received 16 August 2010 remainder of that sheet portion into a folded position, the bin engagement flap being adapted, when in its folded position, and when the pallet bin sheet and pallet are in the assembled condition, to extend through a space between two secondary flaps joined to two adjacent primary flaps. 5

23. A pallet system for forming a pallet, as claimed in any one of the preceding claims, being a knockdown pallet system.

24. A pallet formed from a pallet system according to any one of claims 1 to 10 17.

25. A pallet and pallet bin assembly formed from a pallet system according to any one of claims 18 to 22. Amended Sheet IPEA/AU