NZ330586A - Cardboard pallet - Google Patents

Abstract

A cardboard pallet including: a) a plurality of feet arranged and secured onto a lower surface of a panel of cardboard by way of a substantially planar surface to surface contact area between the upper smooth surface of each foot and a portion of the lower smooth surface of the cardboard panel and b) a base panel constructed from a panel of cardboard secured to a lower surface of each foot thereby providing an upper load-bearing surface of the cardboard panel remote from a ground surface.

Description

Patents Form No. 5 Our Ref: JC210324 NEW ZEALAND PATENTS ACT 1953 Complete After Provisional No. 330586 Filed: 5 June 1998 COMPLETE SPECIFICATION A PALLET AND A METHOD OF CONSTRUCTING A PALLET We, CHARTA PACKAGING LIMITED, a New Zealand company of 20-30 Bell Road South, Gracefield, Lower Hutt, New Zealand hereby declare the invention, for which We pray that a patent may be granted to us and the method by which it is to be performed, to be particularly described in and by the following statement: - 1 PT0579605 intellectual property office of n.z. - 9 JUN 1999 RECEIVED A PALLET AND A METHOD OF CONSTRUCTING A PALLET The present invention relates to a pallet and a method of constructing a pallet. More particularly, the present invention relates to a cardboard pallet and a method of constructing a cardboard pallet.

Background Traditionally timber pallets have been employed where commodities or produce have needed to be transported from one place to another. The timber pallets have been constructed so that a load supporting surface is provided onto which the produce or commodities are packed or placed. The load supporting surface of the pallet is typically constructed from rectangular slats of timber placed side by side and secured onto four inch by two inch slats of timber arranged perpendicular and below the upper layer of slats. Typically the four inch by two inch slats of timber are spaced at regular intervals in such a manner to enable forklift tines to be positioned between the slats to enable the lifting of empty pallets or pallets loaded with produce or commodities.

Difficulties associated with such timber pallets are that they are heavy and expensive to use in non-returnable applications. Such an application occurs when produce or commodities are freighted overseas and the pallets are never returned to the exporter.

A further difficulty can arise from the leaching of timber preservatives into consumable products or such like packed or stacked on top of the timber pallet. The timber pallets are also difficult to secure labels onto, the labels being used to identify the goods or the destination to which the goods are to be carted.

Cardboard pallets have been produced as a lightweight alternative to the timber pallet. An example of such a cardboard pallet is described in New Zealand patent specifications NZ 241164 and NZ 259473.

NZ 241164 discloses a recyclable pallet constructed from paperboard material. Specially prepared pylons (feet) are secured between an upper paperboard panel on which loads are supported and a lower panel. The pylons separate the upper and lower panels sufficiently to allow the insertion of forklift tines. The pylons disclosed Intellectual property office of n.z. - 9 JUN 1999 RtHFIVFD are hollow and typically have a circular or rectangular plan shape. The pylons are secured to the upper and lower layers of paperboard panels. Flaps from the lower panels are cut out and adhesively secured to the pylons. The pylons are secured to the upper layer of paperboard panel with an adhesive.

In NZ 259473 the contacting surface of each foot to the lower pallet body is comparatively minimal. An adhesive is employed in NZ 259473 to secure the base feet to the lower pallet body. In other words a good adhesive bonding surface is not available because of the relatively small surface area to which the adhesive can be 10 applied. During the use of these paperboard pallets it is very easy to dislodge the feet from the pallet because of the minimal adhesive surface to surface contact area between the feet and the pallet.

In NZ 241164, flaps must be cut out of the lower surface of the load bearing pallet 15 surface. Extra machining of the pallet panel is required. The load bearing pallet panels are also difficult to stack once the flaps have been cut out of the pallet panel. The flaps are then used to secure the feet to the pallet by an adhesive. Again the surface to surface adhesive contacting surface is small and these feet are vulnerable to being dislodged or knocked off. Additionally, a further bottom pallet panel is 20 required to provide further support to the feet and add additional robustness to the overall pallet. Likewise, the lower base panel must also be machined to provide flaps which are also adhered to the base of the pallet feet. This process is time consuming and expensive.

It is an object of the present invention to provide a cardboard pallet, which is lightweight, recyclable, of a robust construction overcoming some of the previous mentioned difficulties, and which is useful in export and non-returnable applications, or which at least provides the public with a useful choice.

Further objects will become apparent from the following description.

Statements of Invention According to one aspect of the present invention there is provided a cardboard pallet 35 including a plurality of feet arranged and secured onto a lower surface of a panel of cardboard by way of a substantially planar surface to surface contact area between an upper smooth surface of each foot and a portion of the lower smooth surface of the cardboard panel, and a base panel constructed from a panel of cardboard secured INTELLECTUAL PROPERTY OFFICE OF N.Z. " 5 DEC 2000 RECEIVED - 4 - cr~> c~~ to the lower surface of each foot thereby providing an upper load bearing surface of the cardboard panel remote from a ground surface.

Where the term "cardboard" is referred to throughout the specification, this term 5 includes corrugated cardboard, solid fibre cardboard or composite cardboard and the like.

Preferably the upper and base cardboard panels are constructed from laminated cardboard to provide strength.

In a further aspect of the present invention, there is provided a foot adapted to be secured to a cardboard panel, the foot being constructed from cardboard and is adapted to provide a substantially flat upper surface for substantial surface to surface contact area between the lower surface of a load bearing panel and the upper surface 15 of the foot, in which the foot has at least two side panels extending away from the upper surface of the foot in a substantially perpendicular orientation, to provide an upper load bearing panel surface, when the lower surface of the feet of the pallet are located on a ground surface.

In a further aspect of the present invention there is provided a foot adapted to be secured to a cardboard panel in the construction of a pallet, the foot comprising a single blank of cardboard adapted to provide a substantially square or rectangular base, first and second end walls extending upwardly from the base, the first end wall being further adapted to provide two flaps positionable over the base and from which 25 first and second side wall extend, the second end wall being cut and hinged to provide a second layer of cardboard adapted to be positioned as a second reinforcing layer of each first and second side walls, the first and second side walls further adapted to enable a third layer of side wall to be folded over the second layer of each first and second side walls, the first end wall of the box being adapted to be folded 30 downwardly towards the base layers of the box, the second end wall being adapted to be folded to provide a lid substantially parallel to the base and first and second side tabs extending downwardly from the lid surface and adjacent to the first and second side walls, providing a fourth layer of cardboard reinforcement on the side walls and a flap extending from the lid which folds downwardly and adjacent the first 35 end wall, wherein the flap extending from the lid is secured to the first end wall providing a further cardboard layer of end wall reinforcement.

INTELLECTUAL PROPERTY OFFICE OF N.Z. - 5 DEC 2000 RECEIVED In a further aspect of the present invention there is provided another foot adapted to be secured to a cardboard panel, in the construction of a pallet, the foot being formed from a single blank of cardboard, which is adapted to provide a substantially square or rectangular base, a tab which extends upwardly along the edge of a first 5 end of the square or rectangular base, a second end wall extending upwardly from the rectangular base, which is further adapted to provide a lid which is substantially square or rectangular and mirrors the base shape, the lid having an end flap which is secured to the tab on the first end, the first and second end walls being adapted to provide side flaps which fold towards the opposite end wall thereby providing a first 10 and second side wall, the base being cut and adapted to provide further reinforcing side panels for each first and second side wall, the side panels being notched and adapted to slot into slot cutouts on the lid, the lid being further adapted to provide a third reinforcing layer of side wall for both first and second side walls, in which the third layer of side wall is secured to the second layer of side wall to complete the 15 foot.

In a further aspect of the present invention there is provided another foot adapted to be secured to a cardboard panel, in the construction of a pallet, the foot being formed from a single blank of cardboard to provide a substantially square or 20 rectangular base, first and second end walls extending upwardly from said base, the first end wall being adapted to provide two base flaps which provide a reinforcing base layer over the first base layer, and from which a first and second side wall extend, the second end wall being adapted to provide a second reinforcing layer of cardboard in position over each first and second side wall, the first and second side 25 wall being further adapted to enable a portion of a third reinforcing layer of side wail to be folded over the second layer of each first and second side wall, the first end wall being further adapted to provide a lid substantially parallel to the base and first and second side tabs extending downwardly from the lid surface and adjacent to the first and second side walls, to provide a fourth layer of cardboard reinforcement on 30 the side walls and a flap extending from the lid and which folds substantially downwardly towards the base and which is secured adjacent the second end wall to provide a second layer of cardboard reinforcement at the second end wall.

Preferably, the components of the cardboard pallet are constructed from cardboard, 35 which cardboard is corrugated cardboard to provide further strength. Preferably the flutes of the corrugations are aligned to run parallel to the downwards force applied to any load bearing surface thereby maximising strength. ii*l ttixO i UAL PROPERTY OFFICE OF NI. ;10 JUL 2000 ;ecrFJVFD ;- 6 - ;Further aspects of this invention which should be considered in all its novel aspects will become apparent from the following description which is given by way of example to possible embodiments, and in which reference is made to the accompanying drawings wherein: ;Figure 1 illustrates an embodiment covering the cardboard pallet; ;Figure 2 represents a first cardboard blank which can be employed in constructing a foot of the pallet as illustrated in figure 1; ;Figure 3 illustrates a second cardboard blank which can be employed in constructing a foot of a pallet as illustrated in figure 1; ;Figure 4 illustrates a third cardboard blank which can be employed in constructing a foot of a pallet as illustrated in figure 1 ; ;Figure 5 shows a cut away of a foot according to figure 4, illustrating the plurality of layers extending vertically between the base and lid of the foot, providing strength qualities. ;Detailed Description ;A pallet 1 comprises a top panel 2 of laminated cardboard and a plurality of feet 3. Optionally the pallet may also include a cardboard base panel 4, which is optionally laminated. ;Referring to the top panel of cardboard 2, a number of laminations sheets 5 may be employed to provide a robust and strong top surface layer on which produce and goods can be stacked. Depending on the purpose of application to which the pallet will be exposed, the number of laminations 5 can be determined at the time of construction. ;The base feet are preferably secured to the lower surface of the top panel 2 by an adhesive, double sided tape, or other such securing means. ;If a base panel of cardboard is secured to the bottom of the feet a suitable securing means would be applied to the base of the feet and the bottom panel of the pallet would be applied thereto. ;\ •' * IT!: LLcC"TI ! M property OFFICE i OF N.Z. | - 9 JUN 1999 ' RECEIVED The size of the pallet 1 may be varied according to the application for which the pallet is to be applied.

Figures 2, 3 and 4 illustrate embodiments of cardboard blank which can be employed to construct the base feet. The cardboard blanks 6a, 6b and 6c are constructed from a single panel of cardboard, cut and scored at predetermined positions and folded into shape.

Figure 2 illustrates a first embodiment of a cardboard blank which can be used for constructing a foot 3. The cardboard blank comprises a substantially square or rectangular base portion 7 to which is hinged a flap 8. The flap 8 is covered with an adhesive and folded around to adhere to end wall portion 9 forming a first end wall 10, a lid 11 and a second end wall 9. The side flaps 12, 13, 14 and 15 extending from the base portion 7, the first end wall 10, the lid 11 and the second end wall 9 are folded inwardly and form the first and second side walls of the completed foot. The flaps 14 are folded downwardly from the lid portion 11 towards the base portion 7. The flaps 14 form the outer surface of the side walls. The tabs 16 on flap 1 2 extend upwardly from the base surface 7 and protrude into the cardboard slots 1 7 on the lid portion 11. The final foot is a robust box like container with a multilayered side wall or walls providing significant strength in the direction perpendicular to the planar surface of the base and the lid.

Figure 3 illustrates a further embodiment of a cardboard blank which can be employed to construct a foot. A substantially square or rectangular base 18 is provided. The base has a first end wall 19 connected to a lid surface 20. The blank is cut and scored to provide further base panels 21 and 22 which are folded around and are positioned on the top surface of the base layer 18. When these additional base panels 21 and 22 are in place, a first and second side wall 23 and 24 respectively extend upwardly from the base layers. The second end wall 25 can be folded to extend upwardly from the base layers 18 and 21, 22. The side flaps 26 and 27 of the end wall 25 are additionally folded against the first side layer 23 and the second side layer 24. The side layers 26 and 27, when positioned, reinforce the internal side of the first and second side walls, 23 and 24 respectively. The panels 28 and 29 are folded downwardly and over the side panels 26 and 27 respectively. The panels 28 and 29 effectively lock the side panels into place because of the tolerance provided by the fold 30 and 31. The flaps 32 and 33 on the end of panels 28 and 29 respectively fold over the base portion 21 and 22 respectively when in position. The lid portion 20 has flaps 34 and 35 which can be tucked into the box enclosure providing a further side layer of reinforcement for the first and second side walls 23 and 24, respectively.

INTELLECTUAL PROPERTY OFFICE f of nz 9 JUN 1999 The flap 36 likewise is folded downwardly and is secured to the external surface of the end wall 25. The flap 36 provides a further layer of reinforcing against the second end wall 25. Preferably, the securement is achieved by employing an adhesive.

Figure 4 illustrates a further embodiment of a cardboard blank which can be employed to construct a base foot 3. A substantially square or rectangular base portion 37 is illustrated. The base portion is connected to first and second end walls illustrated as 38 and 39 respectively. Upon construction the end wall 38 extends upwardly from the base portion 37. Flaps 40 and 41 may be positioned to extend over the base portion 37 forming a second base layer. First and second side walls 42 and 43 can be brought into position when panels 40 and 41 are folded over the base layer 37. The second end wall 39 is directly attached to side flaps 44 and 45. Side flaps 44 and 45 provide a further layer of side wall reinforcement and are folded against the first side wall 42 and second side wall 43 respectively. In this position the end wall 39 extends upwardly from the base. Flaps 46 and 47 can be folded over into the base cavity to form a third side wall reinforcement layer against the second layers 44 and 45 of side wall reinforcement. Flap 48 can be folded downwardly over the first end wall layer 38 providing a second end wall layer of reinforcement.

The lid 49 of the foot can be positioned substantially parallel to the base 37. Flaps 50, 51 and 52 which extend from the lid 49 may be folded to lie adjacent to the first and second side walls and the first end wall providing a further layer of reinforcement accordingly. The flap 52 is secured to the external surface of the first end wall by adhesive means.

Figure 5 illustrates the multiple reinforcing layers 53 extending perpendicular to the plane of the lid contacting surface 54 of the foot. The surface area 54 is adhered to the lower surface of the load bearing panel 2 as illustrated in Figure 1.

It is to be appreciated that further variations and modifications may be made to the base feet while still providing a secure cardboard foot which provides a large planar surface area for securing to a cardboard panel to construct a pallet system which is robust and strong. The larger surface to surface bonding area provides robustness to the overall pallet design. For example, it is envisaged that a small lug(s) could be attached to the base foot on the surface which is adhered to the lower panel surface.

IrTfelEcH^l^o^TY"DFRCE OF N.Z. - 9 JUN 1939 RECEIVED The lug(s) could be inserted into a slot(s) cut into the lower panel surface to assist in securing the foot to the panel surface. This modification would also assist in providing further strength if a base foot is subjected to a sideways force.

To construct a cardboard pallet as illustrated in Figure 1, one takes a cardboard blank as illustrated in any one of Figures 2, 3 or 4 and constructs a base foot. Adhesive is applied to either the substantially square or rectangular base, or the substantially square or rectangular lid portion, and applied to the bottom surface of the load bearing panel 3 of the cardboard pallet as illustrated in Figure 1.

The number of feet which are to be attached to the laminated cardboard layer would depend on the load the pallet is to bear, but typically a 3 by 3 configuration or a 4 by 3 configuration can be employed to provide sufficient support to the top load bearing panel of the cardboard pallet.

It is to be appreciated that the orientation of the base feet on the load bearing panel may be varied.

Additionally, the pallet can have a panel 4 attached to the base of the base feet. The bottom panel, however adds considerable bending strength to the whole pallet construction. However, in some instances it is not necessary to employ a bottom panel of cardboard.

The design of the foot is such that it can be mass produced on conventional machinery to minimise costs. The foot is preferably designed from a blank, in a manner to give extra vertical layers of cardboard on edge, as illustrated in Figure 5, providing the load carrying ability of the pallet and to minimise the diagonal raking of the base feet, assisting in overall pallet rigidity.

The advantage of the present pallet design is that the cardboard pallets are light, recyclable, have a low moisture content, labels may easily be printed on or attached to the cardboard and are relatively forgiving while still providing strength and rigidity when transporting commodities, produce or consumables.

Although the present invention has been described by way of example and with reference to possible embodiments thereof, it is to be understood that modifications or improvements may be made thereto without departing from the scope of the invention.

IWTELU^^ OF N.Z. - 9 JUN 1999 RFP.FI\/Fn

Claims (1)

1. WHAT WE CLAIM IS: 5 1. A cardboard pallet including: - a plurality of feet arranged and secured onto a lower surface of a panel of cardboard by way of a substantially planar surface to surface contact area between an upper smooth surface of each foot and a portion of the lower 10 smooth surface of the cardboard panel, and a base panel constructed from a panel of cardboard secured to the lower surface of each foot, thereby providing an upper load bearing surface of the cardboard panel remote from a ground surface 15 2. A cardboard pallet according to claim 1 in which the plurality of feet are arranged and secured onto the lower surface of the upper panel of cardboard in an arrangement adapted to maximise the dispersal of a load on the upper load bearing surface of the cardboard panel. 20 3. A cardboard pallet according to claim 1 or claim 2, in which the plurality of feet are arranged and secured onto the lower surface of the laminated panel of cardboard to provide load bearing support to a load on the upper load-bearing surface of the cardboard panel, while also providing defined channels to provide access for the tines of a forklift device. 25 4. A cardboard pallet according to claim 3, in which said plurality of feet are arranged with one foot at each corner of said upper load bearing surface of the cardboard panel and further feet disposed substantially intermediate at each corner and one foot being located in the centre of said lower surface of the 30 cardboard panel. 5. A cardboard pallet according any one of claims 1 to 4, in which said cardboard includes corrugated cardboard, solid fibre cardboard or composite cardboard. INTELLECTUAL PROPERTY OFFICE OF N.2. - 5 OEC 2000 RECEIVED A cardboard pallet according to any one of claims 1 to 5 in which the upper cardboard panel or lower base panel is constructed from laminated cardboard. A foot adapted to be secured to a cardboard panel of a pallet according to any one of claims 1 to 6 in which the foot is constructed from cardboard and is adapted to provide a substantially flat upper surface for substantial surface to surface contact area between the lower surface of a load bearing panel and the upper surface of the foot, in which the foot has at least two side panels extending away from the upper surface of the foot in a substantially perpendicular orientation, to provide an upper load bearing panel surface, when the lower surface of feet of the pallet are located on a ground surface. A foot according to claim 7 in which the foot is constructed from corrugated cardboard. A foot according to claim 8 in which the corrugations of the side panels and flutes of the corrugations extend away from the upper surface of the foot in a substantially perpendicular orientation and are aligned to run substantially parallel to a substantially downwards force applied to the upper load bearing panel surface. A foot adapted to be secured to a cardboard panel of a pallet according to any one of claims 1 to 6, comprising - a single blank of cardboard adapted to provide a substantially square or rectangular base, - first and second end walls extending upwardly from the base, - the first end wall being further adapted to provide two flaps positionable over the base and from which first and second side wall extend, the second end wall being cut and hinged to provide a second layer of cardboard adapted to be positioned as a second reinforcing layer of each first and second side walls, the first and second side walls further adapted to enable a third layer of side wall to be folded over the second layer of each first and sec JIMtakteTOflUWOPERTY OFFICE OF NX - 5 DEC 2000 RECEIVED - 12 - \Ji \iif - the first end wall of the box being adapted to be folded downwardly towards the base layers of the box, and - the second end wall being adapted to be folded to provide a lid substantially 5 parallel to the base and first and second side tabs extending downwardly from the lid surface and adjacent to the first and second side walls, - to provide a fourth layer of cardboard reinforcement on the side walls and a flap extending from the lid which folds downwardly and adjacent the first 10 end wall, wherein the flap extending from the lid is secured to the first end wall providing a further cardboard layer of end wall reinforcement. 11. A foot adapted to be secured to a cardboard panel, of a pallet according to any one of claims 1 to 6, including: 15 - the foot being formed from a single blank of cardboard and which is adapted to provide a substantially square or rectangular base, - a tab which extends upwardly along the edge of a first end of the square or 20 rectangular base, - a second end wall extending upwardly from the rectangular base which is further adapted to provide a lid, 25 - the lid being substantially square or rectangular and substantially mirrors the base shape, - the lid having an end flap which is secured to the tab on the first end, 30 - the first and second end walls being adapted to provide side flaps which fold towards the opposite end wall to provide a first and second side wall, - the base being further adapted to provide additional reinforcing side panels for each first and second side wall, 35 the side panels being notched and adapted to slot into slot cutouts in the lid of the foot, the lid being further adapted to provide a third reinforcing layer of side wall for both first and second side walls, in which the third laver of side wall is secured to the second layer of side wall to comple t^^(^l^^opPR[y2ERTY - 5 DEC 2000 RECEIVED - 13 - 35 330586 12. A foot adapted to be secured to a cardboard panel of a pallet according to any one of claims 1 to 6 including: 5 - the foot being formed from a single blank of cardboard to provide a substantially square or rectangular base, - first and second end walls extending upwardly from said base, 10 - the first end wall being adapted to provide two base flaps which provide a reinforcing base layer over the first base layer, and from which a first and second side wall extend, - the second end wall being adapted to provide a second reinforcing layer of 15 cardboard in position over each first and second side wall, - the first and second side wall being further adapted to enable a portion of a third reinforcing layer of side wall to be folded over the second layer of each first and second side wall, 20 - the first end wall being further adapted to provide a lid substantially parallel to the base and first and second side tabs extending downwardly from the lid surface and adjacent to the first and second side walls, 25 - to provide a fourth layer of cardboard reinforcement on the side walls and a flap extending from the lid which folds substantially downwardly towards the base and which is secured adjacent the second end wall to provide a second layer of cardboard reinforcement at the second end wall. 30 13. A cardboard pallet according to any one of claims 1 to 5, substantially as herein described with reference to Figure 1. 14. A base foot for use in construction of a cardboard pallet according to any one of claims 1 to 5, substantially as herein described with reference to Figure 2. 15. A base foot for use in the construction of a pallet according to any one of claims 1 to 5, substantially as herein described with reference to Figure 3. INTELLECTUAL PROPERTY OFFICE OF N.Z. - 5 DEC 2000 RECEIVED 330586 16. A base foot for use in the construction of a pallet according to any one of claims 1 to 5, substantially as herein described with reference to Figure 4. CHARTA PACKAGING LIMITED 10 BwItsTAttorneys BALDWIN SHELSTON WATERS INTELLECTUAL PROPERTY OFFICE OF N.Z. - 5 DEC 2000 RECEIVED