WO2004024576A1

WO2004024576A1 - Corregated shipping pallet and support member

Info

Publication number: WO2004024576A1
Application number: PCT/US2003/027784
Authority: WO
Inventors: William W. Pistner; Donald W. Pistner; Daniel H. Pistner; Thomas G. Pistner; Dennis H. Pistner
Original assignee: St Marys Box Co. Inc.
Priority date: 2002-09-11
Filing date: 2003-09-02
Publication date: 2004-03-25
Also published as: EP1539596A1; AU2003263089A1; MXPA05002590A; CA2497063A1; RU2005107583A; EP1539596B1; EP1539596A4; BR0306305A; RU2333875C2; BR0306305B1; CA2497063C

Abstract

The disclosure relates to a lightweight support member (40) or article prepared from corrugated paper which is utilized as a replacement for wood articles such as logs, boards, planks and the like. The support members (40) have a high strength to weight ration and save on transportation and fuel costs. The support members (40) are constructed as a continuous or semi-continuous, flattened or elongated wind of corrugated paper around a core or central area.

Description

CORREGATED SHIPPING PALLET AND SUPPORT MEMBER

CROSS REFERENCE

This application is a continuation-in-part of prior application Serial

Number 1 0/241 ,498, filed September 1 1 , 2002, entitled "Corrugated

Shipping Pallet," herein fully incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to support members which can be

used as a substitute for wood logs, boards, or planking. The support

members are pre erably constructed from corrugated paper and are

lightweight while having high strength. The support members can be

utilized to brace, stabilize, or support various items.

The present invention relates to a pallet or load carrying structure

which can be manufactured from corrugated paper or similar materials

which are recyclable. The pallets are utilized to carry goods, materials,

etc. and are advantageously lightweight, thus saving transportation

costs. The structure of the pallet provides excellent stability and yet

allows for production costs to be minimized.

BACKGROUND OF THE INVENTION

Industries such as transportation and manufacturing have for years

utilized wood articles such as logs, boards, and planking as supports, braces, and separators for various goods or other materials. While wood

articles have been known to be durable, they have numerous drawbacks.

Disadvantages include that wood is relatively dense and thus

heavy. The weight of wood articles increases transportation costs and

reduces the amount of materials which can be transported. A further

disadvantage is that wood surfaces are rough and generally uneven

which can damage the finish of materials, especially fragile materials,

abutted or supported thereby. Moreover, when exposed to moisture,

wood articles can warp, becoming unlevel and not suitable for intended

uses.

A pallet is a portable platform generally including a planar

horizontal member, which can be used as a base member for stacking,

storing, handling and transporting materials or goods. Generally, pallets

are constructed from wood and nails or staples. Recently, pallets have

also been constructed from paper-based materials and plastics. Pallets

generally have openings in the structure thereof to accommodate the

forks of a forklift truck, or the like, and allow the pallet to be lifted off a

floor.

U.S. Patent No. 5,269,21 9 relates to a pallet design for

transporting loads fabricated from paper products consisting of a load-

supporting deck, a top cover sheet with tuck tabs that provides a

fastening and link to the runners, a bottom sheet glued to the deck that provides a solid surface to attach the runners, and runners spaced apart

and at the appropriate height to provide access to the forks on a forklift

or hand jack.

U.S. Patent No. 5,595,1 25 relates to a lightweight, disposable,

corrugated paper pallet formed by a plurality of corrugated paper runners,

traversing the length of the pallet, each runner enveloped by a

continuous corrugated paper inner sheet, which itself is bonded to the

lower side of a reinforced corrugated paper top deck and to the upper

side of a corrugated paper bottom stabilizing deck.

U.S. Patent No. 5,784,971 relates to a collapsible pallet assembly

structure which includes at least a pair of lengthwise beam members and

at least a pair of crosswise beam members formed of a corrugated paper

material. Each lengthwise bead member includes a surface plate portion

from which a plurality of folded sidewall portions extend downward and

at least one wing piece portion projects in substantially coplanar manner.

The surface plate portion has formed therethrough a plurality of upper

slot holes which communicate respectively with a plurality of lower slot

holes formed through the sidewall portions. Each crosswise beam

member includes a top plate portion from which a plurality of folded

bracket plate portions extend downward. Each bracket plate portion

includes a slotted opening that delineates a pair of bracket plate

extending sections. Each crosswise beam member is coupled to the lengthwise beam members in a transverse manner with its top plate

portions partially overlaying at least one of the lengthwise beam

members surface plate portions and with at least one extending section

of each bracket plate portion inserted through an upper slot hole of a

lengthwise beam member surface plate portion.

U.S. Patent No. 5,934,202 relates to a paper pallet which includes

a bottom deck board made of a corrugated paper board, a top deckboard

made of a corrugated paper board, a plurality of paper blocks

longitudinally and transversely arranged in rows and connected between

the bottom deckboard and the top deckboard, and a plurality of paper

packing members respectively adhered between the paper blocks and

one of the bottom deckboard and the top deckboard, the packing

members each having an elongated base adhered between one of the

bottom deckboard and the top deckboard and one row of the paper

blocks and pairs of packing flaps bilaterally extended from two opposite

long sides of the elongated base and respectively adhered to the

corresponding row of blocks at two opposite sides.

U.S. Patent No. 6,357,364 relates to a paper pallet comprising

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.

The prior art paper-based pallets present rather complicated

designs which are not cost effective to produce and are relatively bulky

and heavy. The pallets of the prior art are labor intensive and often not

completely recyclable.

SUMMARY OF THE INVENTION

Support members are disclosed which can be employed as

substitutes for wood braces, supports, or the like. The support members

are preferably constructed from corrugated paper and have a high

strength to weight ratio. The support member is generally formed from

single face corrugated which is wound around a central area or core to

form an elongated body having dimensions similar to the wood article it

can replace.

In a further embodiment, an object of the present invention is to

provide a pallet, preferably constructed of corrugated paper, which while

being lightweight has sufficient strength to support materials or goods to

be transported. Advantageously, the pallet can be recycled and poses

no harmful effects on the environment. A further object of the invention is a pallet structure that is easily

customizable and can be manufactured in a vast number of size ranges

to suit the varying needs of customers.

The pallet of the present invention generally comprises an upper

deck member, a lower deck member, and a plurality of support members

connected therebetween. The upper deck member and the lower deck

member, independently, are disposed at a horizontal plane substantially

parallel to each other as well as a ground surface. The support members

comprise a single continuous wind of corrugated paper linerboard, which

is preferably single faced, having a continuous layer of paper with

strengthening flutes attached thereto. The continuous wind of the

support members provides strength and rigidity to the pallet.

In one embodiment, the pallet is constructed from two or more

support members which substantially extend the length or width of the

deck members and allow two-way access for a forklift truck. In a further

embodiment, the support members include access holes perpendicular to

the longitudinal axis thereof so that the pallet can be accessed from all

four sides for lifting and/or moving. BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood and other features and

advantages will become apparent by reading the detailed description of

the invention, taken together with the drawings, wherein:

FIG. 1 is a perspective view of a corrugated paper pallet of the

present invention showing the upper and lower deck members connected

by support members.

FIG. 2 is an exploded view of a pallet showing the continuous

wind or wrap of the support members.

FIG. 3 is a partial perspective view of a pallet with removed

portions to particularly illustrate the orientation of the flutes of the

corrugated members.

FIG. 4 is a perspective view of a support member which can be

utilized as a substitute for wood pieces.

DETAILED DESCRIPTION OF THE INVENTION

The embodiments of the pallet and associated components thereof

according to the present invention will be specifically described, with

reference to the drawings wherein like numerals indicate like or

corresponding parts throughout the Figures.

FIG. 1 illustrates a pallet 10 of the present invention which

comprises an upper or top deck member 20, a lower or bottom deck member 30, and a plurality of support members 40. The support

members are secured at predetermined locations between the deck

members by a securing means, such as adhesive, tape, fasteners, or the

like, with common white glue being preferred.

The upper deck member 1 0 typically serves as a support or load-

bearing surface for the goods or materials adapted to be stored on and/or

transported by the pallet. The upper deck member is preferably formed

from a single sheet of corrugated linerboard paper. The corrugated paper

can be single wall, double wall or triple wall. As known in the art, single

wall corrugated sheets are formed from two face sheets, 22, 24

connected by a layer of flutes 26, as shown in FIG. 3. The individual

double wall and triple wall corrugated sheets include two and three

layers of fluting, respectively, each separated by a single layer of thin

paper or sheeting, with a layer of the paper or sheeting covering the

outer surfaces of the outer flutes. Accordingly, the double and triple

wall corrugated sheets have alternating layers of flutes and thin paper

layers, with the paper layers being the outer surface of the sheets. The

flutes can be described as having a repeating "S" shaped pattern or

wave profile. The height of the flutes, i.e., from peak to trough, can

vary as known in the art and can be, but are not limited to, A, B, C, and

E grade. When double or greater wall corrugated sheet is utilized,

different grade and thus different heights of flutes can be used in a single sheet of the corrugated paper, with B and C grade preferred for

double wall sheets and A, B, and C; or A, C, and C preferred for triple

wall. The flutes of the corrugated sheeting form hollow tube or straw¬

like passageways and connect the remaining layers together.

Top deck member 20 is a planar structure having a predetermined

length and width, with sizes for both ranging generally from about 1 2 or

14 to about 50 inches, and preferably from about 30 or 40 to about 48

inches.

The main plane formed by the upper deck member is substantially

horizontal and parallel to the lower deck member and adapted to be

parallel with a ground surface. The top member is maintained a

predetermined distance, usually about 3 to about 5 or 6 inches from the

lower deck member 30.

The lower deck member 30 can be formed in the same size,

manner and construction as the upper deck member 20. Depending on

the intended use of the pallet, the corrugated sheets of the upper and

lower deck members can be the same or different such as both being

single wall corrugated paper, or one member being single wall and the

other triple wall, etc. The lower deck member contacts or rests upon the

ground surface. The planes formed by the upper and lower deck

members are, as noted, substantially parallel and thus provide a level

surface for goods or materials. The support member or stringers 40 of the pallet provide both

strength and rigidity to the structure. Each individual support member is

formed from a single continuous piece of corrugated paper, such as

single face. Alternatively, a plurality of pieces such as generally about

1 0 or about 8 or less, desirably about 6 or about 4 or less, and

preferably about 3 or about 2, can be utilized and the same are butted at

their ends to one another, either with or without a fastener such as an

adhesive and wound in the same manner as a single continuous piece of

corrugated paper. The continuous piece of a predetermined height is

wound or wrapped in a direction around itself to form a predetermined

length and width or thickness. Support member 40 is preferably formed

from single face corrugated paper comprising a single layer of paper with

flutes co-extending therewith. Glue or other adhesive is utilized to

secure the continuously wound layers to each other. During formation of

the support member, the glue is preferably applied to the outer flute

edges that will contact the succeeding paper layer. The continuous wind

has a continuous nature of alternating layers of flute and liner or paper.

The overall size of a support member 40 can vary with the height

ranging generally from about 3 inches to about 5 or about 6 inches,

desirably from about 3.5 to about 4 inches, and preferably about 3.5

inches; the width ranging generally from about 2 to about 4 or about 6

inches, desirably from about 2 to about 3 inches, and preferably from about 2 to about 2.5 inches; and the length ranging generally from 12 or

1 4 to about 50 inches; desirably from about 40 to about 48 inches and

preferably from about 46 to about 48 inches.

The support member flutes are arranged parallel to the height of

the support member to provide strength. In this manner, the deck

members will cover the open ends of the support member, which are

then fully enclosed. The overall dimensions of a support member will

vary and depend on the intended use and weight the pallet will be used

to support.

Often a support member will run substantially the entire length of

a pallet from one side or end to another. The number of support

members utilized between the deck members will also depend on the

weight that needs to be supported, and preferably about 2 or about 3 to

about 6 support members are utilized in a pallet.

In a preferred embodiment, the flutes .26, 36 of the deck members

30,40 are disposed in a direction perpendicular to the longest length (as

opposed to the width) of the support members, thus providing strength

to the pallet as shown in FIG. 3. Thus, the flutes of the support

members are perpendicular to the flutes of the deck members. This

configuration is also illustrated in FIG. 2 and has been found to provide a

lightweight, recyclable pallet which is strong and sturdy in construction. As shown at least in FIG. 2, support members 40 preferably have

rounded or curved end portions 42. The curved end portions are adapted

to guide the forks of a fork lift truck into the pallet. This is, the curved

end portions will allow the forks to slide into the passageways formed

between adjacent support members.

FIG. 3 is a detailed cross-sectional view of a pallet of the present

invention, particularly illustrating the orientation of the flutes of the

corrugated members. The flutes 26 of the upper deck member 20 are

orientated in a direction perpendicular to the length of support member

40. The upper deck member is a single wall corrugated paper sheet

having face paper layers or sheets 22 and 24 connected by flutes 26. In

a similar manner, the lower deck member includes face paper layers or

-sheets-32 and 34 connected by flutes 36, which are also orientated

perpendicular to the length of support member 40.

FIG. 4 illustrates a support member 40 which can be utilized to

create a four-way entry pallet. Support member 40 includes at least two

cut-outs 44 which extend completely through the width of the support

member. The size of the orifice or cut-outs can vary and are at least

large enough to accommodate a fork of a fork lift truck. The cut-outs 44

enable the pallet of the present invention to be entered from all four

sides for lifting and moving the same. In a further embodiment, as illustrated in FIG. 2, the lower deck

member 30 can have jack holes 50 formed therein to accommodate lift

wheels of a hand jack. The jack holes 50 can be formed of any shape or

size and are generally at least adapted to be larger than the size of the

lift wheels of the hand jack. Jack holes 50 allow the pallets to be

utilized and lifted by hand jacks which are generally manually operated.

The hand jacks generally include wheels on the fork portions for rolling

movement across the ground surface. The jack holes 50 are adapted to

allow the wheels of a hand jack to be freely moved, as the wheels are

prevented from contacting the pallet 1 0 due to the presence of the

jackholes.

Additionally, either or both of the upper and lower deck members

can be treated with-an oil- and/or water repellent compositions as knαjWiv

in the art and to the literature to prolong the life of the pallet. The

pallets of the present invention being formed of corrugated paper are

completely recyclable and are thus beneficial to the environment. The

construction of the pallet also renders the same insect resistant.

In a further embodiment, a support member or article can be

utilized alone, that is not in a pallet assembly. The support member is

used as a wood substitute and is used as, but not limited to, stack

separators, supports, spacers, braces, stabilizers, and the like. As stated hereinabove, the support members 40 are generally

elongated in length as shown in at least FIG. 4. In addition to the above-

noted size ranges for the support members used in a pallet assembly,

support member construction is versatile and thus a support member is

sized accordingly to fit an intended application. For example, in one

embodiment the support member is used as a brace on the floor of a

truck trailer or rail car; or used between adjacent items or rows of items.

The support member 40 is formed in sizes of about 0.50 x about 2 x

about 2 inches to about 8 x about 8 x about 50 or about 1 00 inches or

from about 1 x about 2 x about 2 inches to about 6 x about 6 x about

50 inches. In further embodiments, the support member is also be

manufactured to typical wood board specifications similar to 2" x 4", 4"

-x- 4", or 2"- x 6" in substantially any desired length. In one embόdirnervt.

two or more support members are glued together, i.e., side by side, one

on top of the other, or the like if desired to provide a larger surface area.

Although the relative size of the support member can vary, the

construction method is generally the same. The support member is

formed as a wind or coil of corrugated paper. The wind is considered a

spiral wind, more specifically a flattened, elongated wind or coil. As

disclosed hereinabove, the support member is preferably formed from

single face corrugated paper having a corrugated paper layer of a

predetermined thickness and a flute layer attached thereto; typically with an adhesive as known in the art. The assembled flattened, spirally

wound or rounded end rectangular support member has alternating layers

of paper sheet and fluting.

As stated hereinabove, the flutes can be, but are not limited to, A,

B, C, or E grade. The paper layer of the corrugated paper generally

ranges from about 23 to about 90-pounds per msf (thousand square

feet) in medium or linerboard as known in the art. Advantageously, the

weight or thickness of the paper is exactly tailored to fit the desired end

use, wherein if more support or strength is needed, a heavier grade of

paper is utilized. Thus, the support members can be custom tailored to

specific applications.

The support member 40 is generally formed in the following

manner. Starting- with = a first end 41 , corrugated paper όiv- a

predetermined height is extended a predetermined length "X" forming a

central area or core 42, preferably in a straight line so that when a

predetermined number of layers are wrapped or wound around the

central core, a support member is formed having a total length L and

width W. When the corrugated paper has been extended to length "X,"

the paper is then bent or folded either clockwise or counter-clockwise

and routed back along and adhered to central core 42. When the first

end 41 is reached, the corrugated paper is wrapped therearound. The process is repeated until the central area is wrapped with a desired

number of layers.

Each layer of paper of the support member is preferably adhered to

an adjacent layer with an adhesive. As illustrated in the FIG. 4, the flute

layers and sheet layers alternate. End 43 of the corrugated paper can be

essentially located at any point along the outside of the support member,

and is not limited as shown in FIG. 4. While the support member can be

formed from a single piece of corrugated paper, it should be understood

that more than one piece can be utilized with ends being abutted or even

slightly overlapped.

The support member of the present invention has excellent

strength. The wrapped structure provides rigidity and stability to the

^■ support member. The curved end portion 45 is very stable and aids in-

preventing separation between the layers. The support member is used

wherever bracing, support or the like are needed. The support member

provides cushioning properties and absorbs vibrations which can occur in

transit, thereby reducing damage to a product. Moreover, the support

member is free of nails, splinters, or other protrusions harmful to

products which can be supported thereby. The support members are

recyclable and repulpable, thereby reducing waste in landfills. EXAMPLES

Example 1

A two-way entry pallet of the present invention was constructed

having an upper deck, a lower deck, and four support members. Both

the upper deck and lower deck had dimensions of 40 inches wide by 48

inches long and were formed from a single sheet of single wall

corrugated paper, 75-pound version. The support members were each

constructed from a single sheet of single face corrugated paper. Glue

was applied to the flute edges and the single piece of single face

corrugated paper was wrapped around itself to form a support member

3 /2 inches high, 48 inches long and 2 inches wide. Two support

members were placed at the width ends with the remaining supports

being - disposed therebetween at equal distance Intervals frorn_; the

remaining support members. The deck members were adhered to the

support members utilizing common white glue.

7,200 pounds of weight was placed on the pallet. The pallet

maintained its initial shape and dimensions and did not deform under the

pressure of the weight for two weeks when the load was removed.

Example 2 - Compression Test

A pallet having the above-noted construction and dimensions as in

Example 1 was placed in a gauged hydraulic press. Pressure was then applied to the top and bottom deck members of the pallet and increased

incrementally. The pallet withstood 1 7,000 pounds of pressure before

being compressed.

While in accordance with patent statutes the best mode and

preferred embodiment have been set forth, the scope of the invention is

not limited thereto, but rather by the scope of the attached claims.

Claims

WHAT IS CLAIMED IS:

1 . A pallet, comprising;

an upper deck member formed from a corrugated sheet;

a lower deck member formed from a corrugated sheet; and

at least two support members, each support member being a solid

wind of contiguous layers of one or more corrugated sheets and each

said support member having a predetermined height, said support

member having a central layer of a predetermined length and additional

said contiguous layers wrapped around said central layer, said support

members connected to both said deck members so that said deck

members are substantially parallel to each other.

2. A pallet according to claim 1 , wherein said support member

corrugated sheet comprises a single paper layer to which a layer of flutes

are attached, and wherein said flutes are arranged in a substantially

vertical direction to the plane of said deck members.

3. A pallet according to claim 2, wherein said support member

is connected to said deck members with an adhesive or fastener, and

wherein each support member, independently, is a wind of about 6 or

less of said corrugated sheets.

4. A pallet according to claim 3, wherein said corrugated

sheets of said deck members comprise single wall, double wall, or triple

wall corrugated sheets.

5. A pallet according to claim 4, wherein said deck member

flutes are arranged in a direction perpendicular to the longest length of

said support member.

6. A pallet according to claim 5, wherein each support

member, independently, is a continuous wind of 2 or less corrugated

sheets, and wherein said flutes of said deck members are arranged

perpendicular to the flutes of said support members.

7. A pallet according to claim 6, wherein said support

members include curved end portions and are formed from a single sheet

of corrugated paper, and wherein each said support member length

extends substantially the length of said deck members.

8. A pallet according to claim 1 , wherein said upper deck

member and said lower deck member have a length of from about 1 2 to

about 50 inches and a width of from about 1 2 to about 50 inches, and wherein said support members have a height of from about 3 to about 6

inches, and wherein each said support member length extends

substantially the length of said deck members.

9. A pallet according to claim 1 , wherein said lower deck

member includes a plurality of jack holes, and wherein each said support

member includes at least two cut-outs which extend completely through

the width of the support member.

1 0. A method for forming a pallet, comprising the steps of:

forming a solid support member from a single sheet of corrugated

paper by continuously wrapping a predetermined number of contiguous

layers -around a central layer, said support member having a

predetermined height, width, and length;

forming at least a second support member; and

connecting an upper deck member and a lower deck member to

said support members with said support members being disposed

between said deck members, said deck members being formed from

corrugated sheets.

1 1 . A method according to claim 1 0, wherein said support

member corrugated paper comprises a single paper layer having a layer of flutes attached thereto, and wherein said support member flutes are

arranged in a substantially vertical direction with respect to at least one

said deck member.

1 2. A method according to claim 1 1 , wherein said support

member is connected to said deck members with an adhesive or

fastener.

1 3. A method according to claim 1 2, wherein said deck

members comprise single wall, double wall, or triple wall corrugated

sheeting.

14. A method according to claim 1 3, wherein said deck merraber

flutes are arranged in a direction substantially perpendicular to the length

of said support member.

1 5. A method according to claim 1 4, wherein said support

members include curved end portions, and wherein each said support

member length extends substantially the length of said deck members.

1 6. A method according to claim 1 5, wherein a plurality of jack

holes are formed in said lower deck member, and wherein each said support member includes at least two cut-outs which extend completely

through the width of the support member.

1 7. A support article, comprising:

one or more pieces of corrugated paper comprising a) a layer of

paper having a length, a width, and a height, and b) flutes connected to

said layer of paper, said flutes arranged parallel to the paper height, said

support article having a core of a predetermined length formed from said

corrugated paper, and said corrugated paper further wrapped around said

core to form said support article having a predetermined length, height, and

width.

1 8. A support article according to claim 1 7, wherein said flutes

are A, B, C or E grade, or a combination thereof, and wherein said layer of

paper is from about 23-pounds to about 90-pounds per thousand square

feet.

1 9. A support article according to claim 1 8, wherein said support

article width, height, and length respectively is from about 0.5 inch by

about 2 inches by about 2 inches to about 8 inches by about 8 inches by

about 50 inches.

20. A support article according to claim 1 9, wherein said support

article width, height, and length respectively is from about 1 inch by about

2 inches by about 2 inches to about 6 inches by about 6 inches by about

50 inches.

21 . A support article according to claim 1 9, wherein one piece of

corrugated paper is utilized to construct said support article.

22. A support article according to claim 19, wherein two or more

pieces of said corrugated paper are utilized to form said support article.

23. A support article according to claim 21 , wherein an adhesive

attaches said corrugated paper wrappings to each other.

24. A support article according to claim 22, wherein an adhesive

attaches said corrugated paper wrappings to each other.