ASSEMBLING THE SAME

FIELD OF THE INVENTION

The present invention relates to a device for transporting and supporting a load and a method of assembling the device thereof.

BACKGROUND OF THE INVENTION

Pallets are widely used in the transportation and storage of goods. The goods (typically packaged in boxes or bags) are stacked on the pallet and bound thereto by straps or wrapping for shipment therewith as an integral unit. Loaded pallets are stored in warehouses either on the floor or in racks in adjacent single or multiple level layers.

Conventional pallets are usually made of wood. Wooden pallets offer good materials handling and stacking strength characteristics. The decreasing supply of readily available wood is raising the cost of such pallets, however, and such wooden pallets are heavy and bulky to transport.

The use of pallets made of corrugated paperboard and similar materials as a substitute for wooden pallets has gained limited acceptance for some applications. Such corrugated pallets are lightweight, relatively maintenance free and readily disposable or recyclable. They may be transported and stored in unassembled form for maximum space utilization when unloaded, and assembled on-site for loading. After usage, they can be broken down for disposal or recycling just like cardboard boxes and other corrugated products.

Known corrugated paperboard pallets provide lightweight, inexpensive alternatives to conventional wooden pallets for some applications, but their strength and rigidity under static and dynamic loading is insufficient to permit wide spread general usage for all types and distribution of goods. Such pallets often have excessive deflection and lack beam strength, which causes their sagging under loads, thereby making the handling, stacking and racking of the pallets impractical and even dangerous. Commonly, loads are mounted upon spaced beams of a rack and the weight of the load is concentrated on the pallet at the beam. Many so called improved pallet designs do not offer the strength necessary to withstand buckling, crushing or compression when placed upon a rack under a load. A suitable pallet for use on a rack must provide minimal compression at the beams of the rack and zero to minimal deflection between the beams of the rack. Known paperboard pallets do not meet these compression and beam strength criteria.

Additionally, known paperboard pallet designs typically become compressed, crushed, milled off or damaged when used under a load being transported on a roller conveyor. Moreover, corrugated paperboard, for instance, may lose up to 50 percent of its stacking strength during conditions of high humidity and moisture when the paperboard absorbs atmospheric moisture and the like.

Thus, there is an increasing need for pallets which are economically and ecologically feasible. However, an acceptable pallet must possess the strength to support their intended loads particularly on a rack or conveyor and must be sufficiently durable to withstand repeated use including being lifted with a lift truck or the like while loaded.

Further, desirably the pallet must resist deterioration by the elements of the weather. Therefore, it is apparent that there is a need in the industry for a pallet which satisfies these and other criteria and overcomes the associated disadvantages and shortcomings of known pallet and runner designs.

The present invention overcomes these and other deficiencies of the above-mentioned drawbacks by providing a device for transporting and supporting a load and a method of assembling the device. The invention provides a considerable reduction of materials with even greater efficiency and economically during operation.

SUMMARY OF THE INVENTION The present invention provides a device for transporting and supplying a load comprising, at least two parallel runners, each runner comprising at least two pairs of substantially vertical oriented reinforcing inserts which spaced apart each other interiorly of the runner; a top wall portion forming a top layer of the runner; a bottom wall portion forming a bottom layer of the runner such that the top wall portion and the bottom wall portion are parallel each other; wherein the reinforcing inserts are positioned between the top wall portion and the bottom wall portion and at least one opening slot is provided on the top wall portion for each reinforcing insert; and at least one panel positioned substantially orthogonal on the runners, the panel having a planar top surface and at least one insertion extended from the planar top surface which disposed into the opening slots of the top wall portion of the runners.

In one embodiment of the present invention, the two runners are placed adjacent to each other and the runner is a longitudinal extent and substantially rectangular cross-section. In yet another embodiment of the present invention, the reinforcing insert is substantially longitudinal extent and substantially rectangular cross-section and the reinforcing insert provides strength and resistance to compression of the runner during use.

In another embodiment of the present invention, the space apart between runners to another provides an opening for allowing a fork of a forklift to be inserted into the opening in a direction substantially perpendicular to the runners for lifting the device.

In one embodiment of the present invention, an interconnection is formed between the panels positioned substantially orthogonal on the runners. In another embodiment of the present invention, the insertion of the panels having a size and a depth equivalent to the size and depth of the opening slot of top wall portion of the runners.

In yet another embodiment of the present invention, a plurality of insertions of the panels is relatively according to a plurality of opening slots of top wall portion of the runners. A means of fixable attaching is provided for the formation of runners and panels to form a rigid structure.

Each components of the device is made from corrugated paper, hardboard, paperboard, cardboard, laminated paper and entirely recyclable and each component of the device is treated for water resistance and water repellency. The device for transporting and supplying a load of the present invention is a paper pallet. Strength of the pallet is able to support a load at least 500 kg to 3000 kg concentrated between the spaced panels of the pallet.

A method of assembling a device for transporting and supplying a load comprising providing at least two pairs of substantially vertical oriented reinforcing inserts which spaced apart each other in between a top wall portion and a bottom wall portion of the runner; attaching and positioning the reinforcing inserts in a predetermined position of the runner; providing an opening slot to the top wall portion for each reinforcing inserts of the runner; arranging at least two runners in a parallel position to each other; and placing at least one panel positioned substantially orthogonal on the runners, the panel having a planar top surface and at least one insertion extended from the planar top surface which disposed into the opening slots of the top wall portion of the runners. A product obtainable from the method of the preceding claims is a paper pallet. The pallet design provides for the ability of the pallet to absorb and withstand motion shock in all directions. By providing for interlocking members between panels and runners, the pallet will not collapse because of any side motion pressure. Prior art pallets do not have this ability and are thus subject to failure when used to transport loads by truck or rail over long distances. Especially, the transportation expense can be advantageously reduced when the pallets are reciprocally used (in a returnable manner) on the cargo loading operation, which cannot be accomplished by the prior resin, wooden or metal pallet. User different size and strength requirements can be met without the need to vary the overall design. Changes in dimensions, weight and type of material utilized, etc., will not interfere with the basic performance characteristics.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

Figure 1 illustrates a device for transporting and supporting a load in accordance of an embodiment of the present invention. Figure 2 illustrates (a) a cross-section view of a panel (b) a perspective view of a panel and (c) a cross-section view of a panel formed from two L-shaped folded papers of the device for transporting and supporting a load in accordance of an embodiment of the present invention.

Figure 3 illustrates an alternative embodiment of a device for transporting and supporting a load in accordance of an embodiment of the present invention. Figure 4 illustrates (a) a cross-section view of a panel (b) a perspective view of a panel and (c) a cross-section view of a panel formed from six L-shaped folded papers of the device for transporting and supporting a load in accordance of an embodiment of the present invention.

Figure 5 illustrates (a) a cross-section view of a panel (b) a perspective view of a panel and (c) a cross-section view of a panel formed from five L-shaped folded papers for fixing to the edge of the device for transporting and supporting a load in accordance of an embodiment of the present invention.

Figure 6 illustrates another alternative embodiment of a device for transporting and supporting a load in accordance of an embodiment of the present invention.

Figure 7 illustrates (a) a cross-section view of a panel (b) a perspective view of a panel and (c) a cross-section view of a panel formed from four L-shaped folded papers of the device for transporting and supporting a load in accordance of an embodiment of the present invention.

Figure 8 illustrates another alternative embodiment of a device for transporting and supporting a load in accordance of an embodiment of the present invention.

Figure 9 illustrates (a) a cross-section view of a panel (b) a perspective view of a panel and (c) a cross-section view of a panel formed from four L-shaped folded papers of the device for transporting and supporting a load in accordance of an embodiment of the present invention. Figure 10 illustrates (a) a cross-section view of a panel (b) a perspective view of a panel and (c) a cross-section view of a panel formed from three L-shaped folded papers for fixing to the edge of the device for transporting and supporting a load in accordance of an embodiment of the present invention. Figure 11 illustrates a perspective view of a runner of a device for transporting and supporting a load in accordance of an embodiment of the present invention.

Figure 12 illustrates a front view of a runner of a device for transporting and supporting a load in accordance of an embodiment of the present invention. Figure 13 illustrates a cross-section view of a runner of a device for transporting and supporting a load in accordance of an embodiment of the present invention.

Figure 14 illustrates a perspective view of a reinforcing insert of a device for transporting and supporting a load in accordance of an embodiment of the present invention.

Figure 15 illustrates (a) a front view of a runner having a pair of reinforcing inserts (b) a front view of a runner having three reinforcing inserts of the device for transporting and supporting a load in accordance of an embodiment of the present invention.

Figure 16 illustrates (a) a front view of a runner having one reinforcing insert (b) a front view of a runner having two reinforcing inserts for fixing to the edge of the device for transporting and supporting a load in accordance of an embodiment of the present invention.

DETAILED DESCRIPTIONS OF THE INVENTION

The present invention will now be described in detail in connection with specific embodiments with reference to the accompanying drawings. Unless the context requires otherwise, throughout the specification and claims which follow, the word "comprise" and variations thereof, such as, "comprises" and "comprising" are to be construed in an open, inclusive sense that is as "including, but not limited to". Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity. Furthermore, in those instances where a convention analogous to "at least one of A, B and C," etc. is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B and C together, etc.). In those instances where a convention analogous to "at least one of A, B or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."

Figure 1 illustrates a device (100) for transporting and supporting a load in accordance of an embodiment of the present invention. The device (100) for transporting and supplying a load of the present invention comprises at least two parallel runners (112), each runner (112) comprising at least two pairs of substantially vertical oriented reinforcing inserts which spaced apart each other interiorly of the runner. To form a device (100) of the present invention also known as a pallet particularly a recyclable paper pallet, two runners are placed adjacent to each other and at least one panel (114) positioned substantially orthogonal on the runners (112), the panel (114) having a planar top surface (116) and at least one insertion (118) extended from the planar top surface (116) which disposed into a plurality of opening slots of the top wall portion of the runners. An interconnection is formed between the panels positioned substantially orthogonal on the runners. The interconnection at each point of intersection between panels and runners by locking and impart sufficient rigidity to the intersection to maintain a fixed relationship between them under longitudinal, lateral and axial rotational forces to be experienced during normal loaded pallet handling. A space apart is formed between the runners to another provides an opening for allowing a fork of a forklift to be inserted into the opening in a direction substantially perpendicular to the runners for lifting the device. The device of the present invention preferably made from paper more particularly corrugated paper, hardboard, paperboard, cardboard, laminated paper or board (also known as flat board), and entirely recyclable.

Figure 2 illustrates (a) a cross-section view of a panel (b) a perspective view of a panel (210) and (c) a cross-section view of a panel formed from two L-shaped folded papers of the device for transporting and supporting a load in accordance of an embodiment of the present invention. The panel (210) is a longitudinal extent and is preferably in downwardly-facing U- shaped for the purposes to fit into the opening slots of the runners to form a pallet. To form a downwardly-facing U-shaped panel of the device of the present invention, the panel is made from a piece of paper folded into downwardly-facing U-shaped as required. Alternatively, the downwardly-facing U-shaped panel is formed from a combination of two L-shaped folded papers (also known as edge board or angle board) (212, 214) which adheres each other. An adhesive is provided for adhering the two L-shaped folded papers such as high strength adhesive glue, staples and other equivalent methods of adherence. The device of the present invention is built up and adhered in face to face relation by an adhesive such as environmental friendly adhesive, biodegradable adhesive or another suitable adhesive commonly known in the industry. Both panel embodiments above provided two insertions that is the end of the downwardly-facing U-shaped to be inserted and fixed rigidly into the runners. A means of fixable attaching such as staples and wires is provided for the formation of runners and panels to form a rigid structure. For application of different weights of a load and reducing materials, a device of the present invention is modified by having an alternative embodiment as illustrated in Figure 3. As shown in Figure 3, the device (310) is formed from a wider planar top surface (312) in each panel (314) with same plurality of runners (316) in Figure 1. However, the opening slots (318) of the runners are required to be modified according to the plurality of the insertion of the panels. The size and depth of the insertion of the panels are equivalent to the size and depth of the opening slot of top wall portion of the runners. Figure 4 illustrates (a) a cross- section view of a panel (b) a perspective view of a panel and (c) a cross-section view of a panel formed from six L-shaped folded papers of the device for transporting and supporting a load in accordance of an embodiment of the present invention. To form the embodiment of the panel of the device of the present invention, the panel is made from a combination of two L-shaped folded papers and two downwardly-facing U-shaped folded papers which adhered to each other. Alternatively, the panel is formed from a combination of six L-shaped folded papers which adhered to each other. Both panel embodiments above provided three insertions in the middle of a device and two insertions at the edge of the device that is to be inserted and fixed rigidly into the runners. Depending on the needs and use, a person skilled in the art is able to modify and providing a panel having a wider planar top surface and higher number of insertions with a different combination.

Figure 5 illustrates (a) a cross-section view of a panel (b) a perspective view of a panel and (c) a cross-section view of a panel formed from five L-shaped folded papers for fixing to the edge of the device for transporting and supporting a load in accordance of an embodiment of the present invention. To form the embodiment of the panel of the device of the present invention, the panel is made from a combination of one L-shaped folded paper and two downwardly-facing U-shaped folded papers which adhered to each other. Alternatively, the panel is formed from a combination of five L-shaped folded papers which adhered to each other. Both panel embodiments above provided two insertions at the edge of the device that is to be inserted and fixed rigidly into the runners.

Figure 6 illustrates another alternative embodiment of a device for transporting and supporting a load in accordance of an embodiment of the present invention. The panel of the this device is formed from two downwardly-facing U-shaped folded papers or alternatively four L-shaped folded papers that adhered to each other as illustrated in Figure 7. Both panel embodiments above provided three insertions in the middle of a device and two insertions at the edge of the device that is to be inserted and fixed rigidly into the runners.

Figure 8 illustrates another alternative embodiment of a device for transporting and supporting a load in accordance of an embodiment of the present invention. To form the embodiment of the panel of the device of the present invention, the panel is made from a combination of two L-shaped folded papers and one downwardly-facing U-shaped folded paper (positioned in the middle) which adhered to each other as illustrated in Figure 9. Alternatively, the panel is formed from a combination of four L-shaped folded papers which adhered to each other. Both panel embodiments above provided two insertions in the middle of a device and two insertions at the edge of the device that is to be inserted and fixed rigidly into the runners. Figure 10 illustrates (a) a cross-section view of a panel (b) a perspective view of a panel and (c) a cross-section view of a panel formed from three L-shaped folded papers for fixing to the edge of the device for transporting and supporting a load in accordance of an embodiment of the present invention. The panel of the this device is formed from one downwardly-facing U-shaped folded paper and one L-shaped folded paper or alternatively three L-shaped folded papers that adhered to each other. Both panel embodiments above provided two insertions at the edge of the device that is to be inserted and fixed rigidly into the runners.

Figure 11 illustrates a perspective view of a runner of a device for transporting and supporting a load in accordance of an embodiment of the present invention. The runner (1200) is a longitudinal extent and substantially rectangular cross-section and made from a sheet or a combination of two sheets of paperboard. A combination of at least two pairs of substantially vertical oriented reinforcing inserts (1210) which spaced apart (1212) each other interiorly of the runner is provided as illustrated in Figure 12. A top wall portion (1214) forming a top layer of the runner (1200) and a bottom wall portion (1216) forming a bottom layer of the runner such that the top wall portion (1214) and the bottom wall portion (1216) are parallel each other. The reinforcing inserts (1314) are positioned between the top wall portion (1310) and the bottom wall portion (1312) as illustrated in Figure 13 and at least one opening slot (1218) is provided on the top wall portion for each reinforcing insert. Each top wall portion (1214) and bottom wall portion (1312) are formed from two-L-shaped folded papers which adhered to each other. Alternatively, each top wall portion (1214) and bottom wall portion (1312) is a downwardly-facing U-shaped folded paper which adhered to each other or to the reinforcing inserts at the sidewalls. In another alternative, the top wall portion (1214) and the bottom wall portion (1312) are formed from one piece folded paper or any form of combination that the person skilled in the art is able to modify.

Figure 14 illustrates a perspective view of a reinforcing insert (1410) of a device for transporting and supporting a load in accordance of an embodiment of the present invention. The reinforcing insert (1410) is preferably made from paper more particularly corrugated paper, hardboard, paperboard cardboard, laminated paper and entirely recyclable. Preferably, the reinforcing insert is recyclable and provides added strength such as a piece of chipboard, fiberboard, linerboard or paperboard. More preferably, the reinforcing insert is a piece of particleboard and, most preferably, a piece of hardboard which provides increased load bearing capability to the runner and associated pallet, increased resistance to compression and is entirely recyclable. The reinforcing insert (1410) is substantially longitudinal extent and substantially rectangular cross-section (also known as square core or square tube). The reinforcing insert (1410) provides strength and resistance to compression of the runner during use.

Figure 15 illustrates (a) a front view of a runner (1510) having a pair of reinforcing inserts (b) a front view of a runner having three reinforcing inserts of the device for transporting and supporting a load in accordance of an embodiment of the present invention. Before formation of the runner, two reinforcing inserts (1512) are adhered to each other to form a pair of reinforcing inserts. This pair of reinforcing insert is placed in between a top wall portion(1514) preferably a downwardly-facing U-shaped folded (as also illustrated in Figure 13) is provided to place on top of the reinforcing inserts and a bottom wall portion (1516) preferably a downwardly-facing U-shaped folded is provided to place at the bottom of the reinforcing inserts. An adhesive is provided such that the position of the reinforcing inserts, top wall portion and bottom wall portion are adhered to each other into a runner having a rigid structure. An opening slot (1518) is subsequently formed and provided on top of the top wall portion (1514) for each reinforcing insert (1512) for allowing insertion from the panel to fix and attach on to the runner. Depending on the needs and use, a person skilled in the art is able to modify and providing a runner having a plurality of reinforcing inserts such as three reinforcing inserts or more with a different combination. Figure 16 illustrates (a) a front view of a runner having one reinforcing insert (b) a front view of a runner having two reinforcing inserts for fixing to the edge of the device for transporting and supporting a load in accordance of an embodiment of the present invention. Depending on the needs and use, a person skilled in the art is able to modify and providing a runner having a plurality of reinforcing inserts such as two reinforcing inserts or more with a different combination.

For formation of the device of the present invention, a method of assembling a device for transporting and supplying a load comprising by firstly provides at least two pairs of substantially vertical oriented reinforcing inserts which spaced apart each other in between a top wall portion and a bottom wall portion of the runner. The reinforcing inserts are then attached and positioned in a predetermined position of the runner. An opening slot to the top wall portion for each reinforcing inserts of the runner. At least two runners are arranged in a parallel position to each other and finally at least one panel is placed and positioned substantially orthogonal on the runners, the panel having a planar top surface and at least one insertion extended from the planar top surface which disposed into the opening slots of the top wall portion of the runners. A tight interlock between the panels and the runners can be performed on-site, just before pallet use, and reinforced by gluing or other common joint securing techniques. In a presently preferred form, each runner of the present invention is approximately 100-120 cm in length, 5-8 cm in width and 10-15 cm in height. Each pair of reinforcing inserts is spaced approximately 10- 5 cm from each other interiorly of the runner. Each runner is approximately 10-15 cm in length, 5-8 cm in width and 4-6 cm in height. The panel is approximately 100-120 cm in length and a planar top surface of approximately 100- 120 cm in length and 10-15 cm in width surface thereof with the depth of the insertion approximately 3-5 cm. Other materials may be added during manufacture to improve certain properties such as stiffness, hardness, finishing properties, resistance to abrasion and moisture, as well as to increase strength, durability and utility. For avoiding humidity environment, each component of the device is treated for water resistance and water repellency. The device of the present invention provides strength of the pallet supports a load at least 500 kg to 2500 kg concentrated between the spaced panels of the pallet.

One of the advantages of the device of present invention is that it possess the strength to support the intended loads particularly on a rack or conveyor and must be sufficiently durable to withstand repeated use including being lifted with a lift truck or the like while loaded. Another advantage of device of the present invention is that it provides a pallet which is economically and ecologically feasible. Further advantage of the present invention is that a lightweight, but durable and cost-effective pallet is produced. The stable configuration of the pallet allows for part of the pallet to experience damage without destroying the integrity and usability of the remaining portion. The pallet design provides for the ability of the pallet to absorb and withstand motion shock in all directions. By providing for interlocking members between panels and runners, the pallet will not collapse because of any side motion pressure. Prior art pallets do not have this ability and are thus subject to failure when used to transport loads by truck or rail over long distances. Especially, the transportation expense can be advantageously reduced when the pallets are reciprocally used (in a returnable manner) on the cargo loading operation, which cannot be accomplished by the prior resin, wooden or metal pallet. User different size and strength requirements can be met without the need to vary the overall design. Changes in dimensions, weight and type of material utilized, etc., will not interfere with the basic performance characteristics.

The foregoing embodiment and advantages are merely exemplary and are not to be construed as limiting the present invention. The description of the embodiments of the present invention is intended to be illustrative and not to limit the scope of the claims and many alternatives, modifications and variations will be apparent to those skilled in the art.