FIELD OF THE INVENTION This invention relates to a pallet and more particularly to a pallet made of stiff, foldable sheet material such as corrugated cardboard.

BACKGROUND OF THE INVENTION Lightweight pallets made of corrugated cardboard are known, as disclosed for example in United States Patent No. 4,792,325 issued December 20, 1988 to Joachim G. Schmidtke, United States Patent No. 4,867,074 issued September 19, 1989 to Robert J. Quasnick, and United States Patent No. 5,001,991 issued March 26, 1991 to Daniel A. Smith. Each of these three references discloses a corrugated cardboard pallet having intersecting stringers and runners forming a platform, both the stringers and runners being separately constructed of multi-layered panels. Such pallets are relatively expensive to fabricate.

It is an object of the present invention to provide a lightweight pallet of simple construction which is inexpensive to fabricate.

SUMMARY OF THE INVENTION

The subject invention provides a pallet for supporting loads. In one aspect the pallet includes a

SUBSTITUTESHEET

first rectangular sheet of stiff, foldable material having opposed side and end edges and having a central portion and opposed side edge portions. The central portion has a top and bottom surface and the side edge portions each are folded into a plurality of parallel panels to form rectangular first and second channel members beneath the bottom surface of the central portion forming a platform. The outermost panels of the sheet are provided with transverse slits such that each of said outermost panels has at least one first tab and at least one second tab. The central portion has a plurality of first slots located in two spaced rows with the first slots being suitable to receive the first tabs. The at least one first tab of each outer panel is inserted through the first slots of one of said rows of first slots and folded to overlay a portion of the central portion top surface of the first sheet and is secured thereto. The at least one second tab of each outermost panel is folded to underlie the bottom surface of the central portion and is secured thereto. The at least one first and at least one second tab of the outermost panels form an array of tabs alternately overlaying and underlaying the central portion respectively. The pallet includes at least one second rectangular sheet of stiff, foldable material folded into a plurality of parallel panels to form at least a third rectangular channel member with the outermost panels extending laterally from said at least a third rectangular channel member and

being provided with transverse slits to provide a plurality of third tabs. The central portion of the first sheet has a plurality of second slots located between the two rows of the first slots to receive the third tabs with the third tabs being inserted through the second slots of the first sheet and folded to overlay a portion of the central portion of the first sheet and being secured thereto. The channel members are for receiving vertical reinforcement means. The pallet may be reinforced by providing a plurality of crossbraces, each crossbrace comprising a rectangular sheet of stiff material folded into a plurality of panels lying face to face, channel members each having apertures adjacent the platform forming lateral passages to receive the crossbraces.

In another aspect of the invention, a pallet blank is provided and comprises a first rectangular sheet of stiff, foldable material having opposed side and end edges and having a central portion and opposed side edge portions. The central portion has a top and bottom surface. The side edge portions each are foldable into a plurality of parallel panels to form rectangular first and second channel members beneath the bottom surface of the central portion forming a platform. The outermost panels of the sheet are provided with transverse slits such that each of the outermost panels has at least one first tab and at least one second tab. The central portion has a plurality of first slots located in two

spaced rows. The first slots are suitable to receive the first tabs and the at least one first tab of each outer panel is insertable through the first slots of one of said rows of first slots and foldable to overlay a portion of the central portion top surface of the first sheet. The tabs are securable to the top sheet and the at least one second tab of each outermost panel is foldable to underlay the bottom surface of the central portion and is securable thereto. The at least one first and at least one second tab of the outermost panels form an array of tabs alternately overlaying and underlaying the central portion respectively when the pallet blank is assembled to form a pallet. The pallet blank includes at least one second rectangular sheet of stiff, material foldable into a plurality of parallel panels to form at least a third rectangular channel member. The outermost panels extend laterally from said at least a third rectangular channel member and are provided with transverse slits to provide a plurality of third tabs. The central portion of the first sheet has a plurality of second slots located between the two rows of the first slots to receive the third tabs. The third tabs are insertable through the second slots of the first sheet and foldable to overlay a portion of the central portion of the first sheet and being securable thereto. The channel members are for receiving vertical reinforcement means.

In another aspect of the invention, a pallet is provided which comprises a first rectangular sheet of stiff, foldable material having opposed side edge portions, opposed end edges and having a central portion, the central portion having a top and bottom surface, the side edge portions each being folded into a plurality of parallel panels to form rectangular first and second outer channel members beneath the bottom surface of the central portion, the outermost panels of the sheet being provided with transverse slits such that each of said outermost panels has at least one first tab and at least one second tab, the central portion being folded into a plurality of parallel panels to form at least one rectangular channel member beneath the bottom surface of the remainder of the central portion between said outer channel members, the central portion having a plurality of first slots located in two spaced rows, the first slots being suitable to receive the first tabs. The pallet includes at least one second rectangular sheet of stiff, foldable material having opposed end edge portions and opposed side edges, said second rectangular sheet of material overlaying said central portion forming a load support surface, said second rectangular sheet being secured to said first sheet, said second sheet having a plurality of first slots located in two spaced rows, the first slots being suitable to receive the first tabs, said first slots in said second sheet being in registration with said first slots in said first sheet,

the at least one first tab of each outer panel being inserted through the first slots of one of said rows of registered first slots in said first and second sheets and folded to overlay a portion of the top surface of the second sheet and being secured thereto, the at least one second tab of each outermost panel being folded to underlay the bottom surface of the central portion of the first sheet and being secured thereto, the at least one first and at least one second tab of the outermost panels forming an array of tabs alternately overlaying and underlaying the second and first sheets respectively. The channel members are sized for receiving vertical reinforcement means.

BRIEF DESCRIPTION OF THE DRAWINGS

The following is a description, by way of example only, of various embodiments of the invention, reference being had to the accompanying drawings, in which: Figure 1 is a perspective view of a pallet constructed in accordance with the present invention;

Figure 2 is a cross-sectional view taken along line 2-2 of Figure 1;

Figure 3 is a perspective view of one of the reinforcing cores shown in Figures 1 and 2;

Figure 4 is a plan view of a sheet of material foldable to form the basic structure of the pallet of Figure 1;

Figure 5 is a plan view of a sheet of material foldable to form the central support of the pallet of Figure 1;

Figure 6 is a perspective view of a first alternate embodiment of the pallet of Figure 1;

Figure 7 is a perspective view of a second alternate embodiment of the pallet of Figure 1;

Figure 8 is a plan view of a sheet of material foldable to form each of the crossbraces of the pallet of Figure 7;

Figure 9 is a cross-sectional view of one of the crossbraces of the pallet of Figure 7;

Figure 10 is a plan view of a sheet of material foldable to form the basic structure of the pallet of Figure 7;

Figure 11 is a plan view of a sheet of material foldable to form the central support of the panel of Figure 7;

Figure 12 is a perspective view of a third alternate embodiment of a pallet constructed in accordance with the present invention;

Figure 13 is another perspective view of the pallet of Figure 12 but looking from below the pallet; Figure 14 is a perspective view of a fourth alternate embodiment of a pallet constructed in accordance with the present invention; and

Figure 15 is another perspective view of the pallet of Figure 14 but looking from below the pallet.

DETAILED DESCRIPTION OF THE INVENTION

The example embodiment shown in the drawings consists of a pallet 10 of rectangular configuration having a deck or platform 12, first and second parallel channel members or stringers 18 located on the underside of the platform along two opposed side edges 20 of the platform, and a third channel member 22 centrally located on the underside of the platform parallel to channel members 18. Each channel member 18 and 22 is rectangular in cross-section and contains a plurality of spaced reinforcing members 24 extending the height thereof for vertical support.

The construction of pallet 10 uses a first sheet 26 of stiff, foldable material slit and slotted as shown in Figure 5 of the drawings. Sheet 26 is rectangular with opposed pairs of side edges 28, and opposed pairs of end edges 30. Four fold lines 32, 34, 36 and 38, adjacent each side edge 28 and parallel thereto, delineate panels 40, 42, 44 and 46 respectively, of equal width. Two rows of slots 48, each spaced inwardly from opposed end edges 30 of sheet 26, are located along lines parallel to fold lines 38 and spaced inwardly therefrom a distance equal to the width of panel 44. Two rows of slots 50 are located one on each side of centreline 52 of sheet 26. Each outermost panel 40 has pairs of slits 54 which extend inwardly from its side edge 28 to form tabs 55 foldable along line 32, the location of tabs 55 between end edges 30 corresponding to

the location of slots 48 between the end edges. Rectangular pairs of apertures 57 are located in each of panels 42 and 46 of sheet 26 approximately one-third the length of the panels from each side edge 28 of the sheet, extending between fold lines 32,34 and 36,38 respectively.

A second rectangular sheet 56 of stiff, foldable material, used to form a central channel member 22, has a pair of opposed side edges 58 and a pair of opposed end edges 60. Four fold lines 62, 64, 66 and 68, parallel to side edges 58, delineate five panels 70, 72, 74, 76 and 78 of equal width. Pairs of slits 80 in outermost panels 70 and 78 extend inwardly from each side edge 58 of sheet 56 and terminate at the first fold line 62 and 68 respectively to form tabs 82 foldable along lines 62 and 68. The location of tabs 82 between end edges 60 corresponds to the location of slots 50 between end edges 30 of sheet 26. Rectangular apertures 83 are located in each of panels 72 and 76 of sheet 56 the same distance from end edges 60 as the distance of apertures 57 from side edges 28.

Pallet 10 is fabricated by folding each side 28 of sheet 26 on fold lines 32, 34, 36 and 38 as seen in Figure 5 to form panels 42, 44 and 46 constituting first and second channel members 18. Before the folding procedure is commenced, reinforcing members 24 are attached at one end to panels 44 of sheet 26. In the example embodiment reinforcing members 24 are tubular

cores. When panel 40 is folded along line 32, tabs 55 are left unfolded and when that panel is brought around to lie against the underside of sheet 26 the tabs are inserted through slots 48, folded down in the opposite direction to panel 40 to lie against the upper side of sheet 26, and secured to the sheet. When channel members 18 are formed, reinforcing members 24 abut panels 40.

Third channel member 22 is formed by folding sheet 56 along lines 64 and 66 to form panels 72, 74, and 76. Sheet 56 is also folded along lines 62 and 68 to form panels 70 and 78 extending laterally outward from the channel with tabs 82 extending upwardly. Reinforcing members 24 are attached at one end to panel 76. Tabs 82 are inserted through slots 50 in sheet 26 and folded down onto the upper side of the sheet. Panels 70 and 78 and tabs 82 are then fixed to sheet 26. Reinforcing members 24 abut sheet 26. Also, apertures 83 in channel member 22 are in alignment with aperture 57 in channel members 18 to form a pair of lateral passages extending through all channel members 18 and 22 normal thereto.

Preferably the material of sheets 26 and 56 is corrugated cardboard of suitable type and quality to provide the strength required to bear the load for which the pallet is to be used. Tabs 55 and 82, and also panels 40, 70 and 78, are preferably secured by glue to sheet 26.

The first alternate embodiment of the invention shown in Figure 6 consists of a pallet 90 similar to the

pallet of Figure 1 except that sheet 26 is laminar having an upper lamina 92 and a lower lamina 94. The side edge portions of upper lamina 92 are folded to form channel members 18. The side edges 96 of lower lamina 94 terminate at panels 46 and the end edge portions 98 extend beyond end edges 100 of the upper lamina and are folded up and back over the upper lamina and secured thereto. This provides added strength to the pallet. Also when the pallet is made of corrugated cardboard further strength is obtained by having the corrugations of lamina 92 run perpendicular to the corrugations of the lamina 94 of sheet 26.

A second alternate embodiment of the invention is shown in Figures 7 to 11 inclusive in which a pallet 101 has a plurality of transverse reinforcing members or crossbraces 102 are located beneath platform 12 intermediate its end edges 30. Crossbraces 102 are each formed from a sheet 103 of stiff, foldable material divided as shown in Figure 8 preferably into ten parallel panels 104 to 113 inclusive by score lines 115 to 123 as follows: lines 115, 117, 119 - reverse slit scoring (cut through one or more layers on reverse side and creased, shown by broken lines); lines 116 and 118 - slit scoring (cut through one or more layers and creased, shown by solid lines); lines 120 to 123 - scoring (creased, shown by chain dotted lines).

For increased strength, corrugations 114 are preferably aligned normal to score lines 115 to 123. As seen in Figure 9, panels 104 to 109 are folded along lines 115 to 119 in back-to-back relationship and panels 110 to 113 are folded along lines 116 to 123 to circumscribe folded panels 104 to 109. If desired, sheet 103 may be completely severed along one or more score lines 115 to 123 or each crossbrace 102 may be built up entirely of separate panels. To accommodate crossbraces 102, rectangular apertures 124 are suitably located in panels 42 and 46 of sheet 26 adjacent fold lines 32 and 38. Each panel 42 and 46 also carries a reinforcing strip 126, preferably of the same material as sheet 26, fixed to the panel, as seen in Figure 10. Similar apertures 128 are located in panels 72 and 76 of sheet 56 adjacent fold lines 62 and 68, and panels 72 and 76 also carry reinforcing strips 130, as seen in Figure 11. In this embodiment apertures 57 in panels 42 and 44 of sheet 26, and apertures 83 in panels 72 and 76 of sheet 56 are not present.

The assembled structure of the second alternate embodiment is shown in Figure 7. Crossbraces 102 lie in groups between reinforcing members 24 and adjacent the underside of platform 12, passing through apertures 124 of outer channel members 18 and apertures 128 of central channel member 22, and having their ends preferably flush with the outer face of each of the outer channel members. It is preferable to have apertures 124 lie along fold

line 32 between tabs 55 and to have apertures 128 lie along fold lines 62,68 between tabs 82.

Reinforcing members 24 may be fabricated of any foldable, corrugated recyclable paper product folded in a fashion which is sufficient to support top-to-bottom compression when the pallet is under load. In addition, tubular cores cut from paper rolls such as shown in Figure 3 may be used. Reinforcing members 24 fit into channel members 18 to abut panels 40 and 44 and fit into channel member 22 to abut sheet 26 and panel 74, being preferably secured by glue where they abut.

It will be appreciated that the pallet of the invention is lightweight but strong. Also the pallet may be fabricated solely from paper products with no plastic or metal fasteners, thus making it easily recyclable which is a feature increasingly demanded by purchasers of this product.

The material of sheets 26, 56 and 102 is preferably corrugated cardboard, as mentioned above. A suitable type is A, B, C, E or jumbo flute, which may be used in any combination if the sheets are laminated and added strength is obtained by having the laminations in a cross-corrugated pattern. In addition, combinations of double wall, triple wall or quadruple wall corrugated cardboard may be used in any combination with itself or with a single wall. To increase the resistance to moisture and the elements, the sheet material forming the pallet may be constructed of wet strength or water

resistant adhesives and/or wet strength or weather resistant liners, and may be constructed of fully hydrochem mediums.

It will be appreciated that apertures 57 and 83 in channel members 18 and 22 are not essential but provide a four-way entry into pallet 10 or 90. Apertures 57 and 83 may be perforated and may be knocked out by a user at his option.

The structure of the pallet of the present invention is not restricted to three stringers or channel members as shown in the example embodiment since more than one channel member 22 may be attached to sheet 26. Also, channel members 16 need not be square in cross- section as shown in the example embodiments, and the number of tabs 55 and 82 may vary, and the number of cores 24 may vary.

Referring to Figures 12 and 13, another embodiment of the inventive pallet is shown generally at 200. Pallet 200 as illustrated comprises a bottom support base 202 fabricated of a sheet 203 of stiff material folded to form three integral channel members or stringers including two outer channel members 204 and a central channel member 206. Base 202 includes end edges 208 and side edge portions 210 which are folded to form outer channel members 204. Pallet 200 includes a sheet 212 of stiff material overlaying and secured to base 202 thereby forming a top deck or platform 214.

Sheet 212 includes end edges 215 (Figure 13) and side edges 216 and includes cut-outs along the end edges thereof adjacent central channel member 206 thereby forming tabs 220 which are folded over end edges 208 of base 202 and secured to the underside of the sheet forming the support base, best seen in Figure 13. Outer channel members 204 are secured to deck 214 ±>y transversely slitting the outermost panels formed in side edge portions to form tabs 230 and 232 (only one tab 232 is visible in Figures 12 and 13). Sheet 203 is provided with slots (not shown) to receive tabs 230 therethrough. These slots are in registration with slots 234 in sheet 212. Tabs 230 are inserted through the registered slots located in sheets 203 and 212 and overlay and are secured to the top surface of sheet 212. Tabs 232 underlay the bottom surface of sheet 212 and are secured thereto by gluing or other bonding technique.

Central channel member 206 is fixed in position by tabs 220 of sheet 212 attached to the underside of the sheet 203 forming base 202. Channel member 206 may be further secured by cutting sheet 203 at 240 (Figure 13) to form tabs 242 (Figure 12). Tabs 242 are inserted through slots 244 located in sheet 212 and are folded to overlay sheet 212 and secured thereto. Referring to Figures 14 and 15, another embodiment of a pallet forming the present invention is shown generally at 260. Pallet 260 is identical to pallet 200 except for the absence of tabs 242. It will

be appreciated that tabs 242 are optional when the central channel member is integrally formed from the support sheet 203 since the portions of support base 202 underlaying sheet 212 can be secured directly thereto by gluing and the like.

The embodiments of the pallet illustrated in Figures 12 to 15 avoid the need for a separate central channel member which is more economical and since the central channel member is integrally formed with the support base there is a strong connection between the central channel member and the rest of the pallet. It will be appreciated by those skilled in the art that the embodiments of the pallet disclosed herein may be fabricated and shipped as a blank and then assembled for use by an end user.

While the pallet fabricated from stiff foldable material has been described and illustrated with respect to the various embodiments disclosed herein, it will be appreciated that numerous variations of these embodiments may be made without departing from the scope of the invention.