CA2119591A1

CA2119591A1 - Recyclable paperboard pallet and method of fabrication

Info

Publication number: CA2119591A1
Application number: CA 2119591
Authority: CA
Inventors: Jean Raymond
Original assignee: Cascades Inc
Current assignee: Cascades Inc
Priority date: 1994-03-22
Filing date: 1994-03-22
Publication date: 1995-09-23

Abstract

ABSTRACT
RECYCLABLE PAPERBOARD PALLET
AND METHOD OF FABRICATION

A recyclable paperboard pallet and method of fabrication is described. The pallet is formed by gluing together two cardboard blanks to form a flat support platform. One of the blanks has cylinder-receiving holes therein and positioned at predetermined locations. Support cylinders constructed of solid paperboard material are glued to each of these holes.
The cylinders have free ends to support the platform elevated from a support surface. A bottom support platform also having cylinder-receiving holes in one of its blanks may also be connected by glue to the free ends of the cylinders to form a double platform pallet.
All of the material utilized in the construction of the pallet is recyclable and there are no metal parts, such as staples. Also, the pallet is preferably formed with-corrugated cardboard to constitute the support platform and solid paperboard for the cylinders.

Description

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TECHNICAL FIELD
The present invention relates to a recyclable paperboard pallet and a method of fabricating same, and further wherein solid paperboard cylinders are secured in cylinder-receiving holes formed in one of the blanks utilized to form a top support platform and optionally also in a bottom support platform.

BACKGROUND ART
It is well known in the art to fabricate pallets from paperboard products and, as an example thereof, one such pallet is described in U.S. Patent 3,464,371.
However, in such pallets staples and glue are often used to interconnect pallet pieces together although some of the patents may not show such staples. In U.S.
Patent 3,407,758 there is also disclosed a cardboard pallet incorporating support posts therein which are formed of defective metal containers in order to find a use for such containers. It is also frequent in the construction of cardboard pallets to utilize reinforcing lumber pieces, such as disclosed in U.S.
Patent 4,863,024. The construction of such pallets make it substantially impossible to recycle them and to make other or similar paperboard products therefrom.
Another disadvantage of paperboard pallets is that some of these are not very strong, are difficult and time consuming to construct, and have limited applications.
Furthermore, these pallets are often heavy and the use of wood therein makes it dangerous to the hands of the user in that splinters can locate themselves in the fingers of the user. These pallets are also usually of a single rectangular shape and it is difficult to make pallets of different shapes due to the fact that support legs are formed from a single sheet of cardboard material which is simply bent over along parallel fold lines to form hollow rectangular :~ .

cylinders to act as legs and these are then fortified by using wood or other stronger materials.

SUMMARY OF INVENTION
It is a feature of the present invention to provide a completely recyclable paperboard pallet and a method to fabricate same which substantially overcomes the above mentioned disadvantages of the prior art.
Another feature of the present invention is to provide a completely recyclable paperboard pallet which is lightweight and which is capable of carrying heavy loads of over 2~ tons, and wherein the pallet can be constructed with a variety of shapes and paperboard material weights, and in a fast and efficient manner thereby reducing the cost of the pallet.
According to the above features, from a broad aspect, the present invention provides a method of :- ~: ~ :. .
fabricating a paperboard pallet which is entirely recyclable. The method comprises cutting from a cardboard material at least two support blanks to form a flat support platform having at least two paperboard layers. Cylinder-receiving holes are cut in one of the support blanks at predetermined locations before the flat support platform is formed. Glue is applied to a surface of the other blank. The two blanks are then .~
superimposed to bond them together with the surface having glue thereon. An end of a plurality of cylinders, constructed of solid paperboard material, is positioned in a respective one of the cylinder~
receiving holes in the support blank having the holes `~
therein to contact the surface of the other blank on ;~
which glue has been applied to bond the cylinders into -~
the holes. The cylinders have free ends which, when positioned on a support surface, maintain the support ~
platform elevated therefrom. `- ~;-According to a further broad aspect of the present invention a further bottom support platform, ,~ .:' ~ ` -',. ' ' '~ .

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formed similarly to the top support platform, is positioned at the free ends of these cylinders which are received in cylinder-receiving holes of the second blank thereby attaching the second blank to the cylinders.
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According to a still further broad aspect of the present invention the support platforms are each formed by cutting the two support blanks in a single sheet of cardboard material with the blanks interconnected side by side by a slit hinge line, and the blanks are then folded together along that hinge line to interconnect them together as above described.
According to a still further broad aspect of the present invention the method comprises cutting from a cardboard material two support surface blanks to form a support platform. Glue is applied to a surface of one of the blanks. The blanks are superimposed together to bond them by the surface having glue thereon.
Cylinder-receiving cavities are embossed in one of the support surface blanks at predetermined locations.
Glue is applied in the cylinder-receiving cavities. A
cylinder constructed of solid paperboard material is then positioned in the cylinder-receiving cavities and bonded therein by the glue. The cylinders have free ends which, when positioned on a support surface, maintain the support platform elevated therefrom.
According to a still further broad aspect of the present invention there is provided an entirely recyclable paperboard pallet which comprises a flat support platform formed by two support blanks of corrugated cardboard folded together along a hinge line in superimposition and glued together. A bottom one of the blanks has a plurality of cylinder-receiving cavities formed therein at predetermined locations. A
solid paperboard cylinder is secured in each of the cylinder-receiving cavities by glue to bond the cylinder thereto. The cylinders have free ends which, : . ~ . .: .:.: - .,~

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BRIEF DESCRIPTION OF DRAWINGS
A preferred embodiment of the present invention will now be described with reference to the accompanying drawings in which:
FIG. l is a perspective view of an example of a paperboard pallet constructed in accordance with the present invention;
FIG. 2 is a perspective view showing another example of the paperboard pallet of Fig. l, and wherein a bottom support platform has been secured to the -~
cylinders;
FIG. 3 is a bottom perspective view of Fig. 2;
FIGS. 4A and 4B are plan views of a top support platform showing each of the two support blanks used to form the flat support platform of the present invention;
FIG. 5 is a perspective view of a top support platform showing the two support blanks formed from a single cardboard material sheet and hingeable in superimposition along a hinge linei ~- -FIGS. 6A and 6B are plan views of the two support blanks which are superimposed and glued together to form a bottom support platform;
FIG. 7 is a plan view showing the two support blanks formed from a single cardboard sheet and foldable in superimposition along a fold line to form a bottom support platform;
FIG. 8 is a perspective view showing the two support blanks in the process of being folded together;
and , FIG. 9 is a fragmented cross-section view showing the construction of a sùpport platform and how ~ - `
the cylinders are received in the cylinder-receiving cavities. ~ `-';`''`''.``''.'-''i'-''"`''`' '`'`""

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DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings and more particularly to Figs. 1 to 3, there is shown generally at 10 and 10' two entirely recyclable paperboard pallets constructed in accordance with the present invention. As shown in Fig. 1, the pallet consists essentially of a flat support platform 11 which is supported elevated from a ground surface by a plurality of cylinders 12 which are constructed from solid paperboard material. The support platform 11 is constructed of two or more corrugated cardboard layers -~
or blanks formed from each having at least two corrugated layers bonded together. Solid paperboard could also be used. ~-: .
The pallet as shown in Figs. 2 and 3 further comprises a bottom support platform 13 connected to the opposed free ends 14 of the cylinders 12 in a manner as will be described later. As shown in Fig. 3, the bottom support platform 13 is further provided with a plurality of clearance holes 15 to permit the passage of portions of wheels (not shown) when the pallet is lifted by a mechanically controlled lift dolly (not shown), but well known in the art.
Referring now to Figs. 4 to 9 there will be described the detailed construction of the pallets 10 and 10'. As shown in Figs. 4A and 4B, the support platforms 11 and 13 are formed by two support corrugated cardboard blanks 16 and 17 which are die-cut to size. It is pointed out that, although this pallet is of a substantially rectangular configuration, the configuration thereof can be modified to substantially any shape. Round pallets could be formed by cutting round cardboard blanks and these are practical to support paper rolls from mills. One of the blanks, herein blank 16, has a plurality of cylinder-receiving holes 18 cut thereacross, and these are positioned at :,:, :,:-,"- ",,, predetermined locations, as herein shown, to provide suitable weight transfer and distribution of a load placed on the upper support platform 11 of the pallet.
- On the surface 17' of the other cardboard blank S 17 glue is applied thereacross. Alternatively, glue could be applied in glue strips 19 at locations which will register with the cylinder-receiving holes 18 when the surface 17, is superimposed in registry over the cardboard blank 16. When these surfaces are superimposed, as shown in Fig. 9, the glued surface 17 will appear at the bottom of the cavities 18, as shown in Fig. 9. A plurality of the cylinders 12 are then positioned within a respective one of the holes or cavities 18 and will be retained therein by the glue 19 lS which is present on the bottom wall thereof. The cylinders 12 are thus secured to the top support platform 11 in an efficient and rapid manner.
As shown in Figs. 5 and 9, this top platform may also be formed from a single sheet of cardboard material 20 and the blanks 16 and 17 are interconnected in side-by-side relationship by a slit hinge line 21.
Glue is applied to the surface 17', in the same manner as previously discussed with reference with Fig. 4B, and the blank 17 is folded over the blank 16 in the manner as shown in Fig. 8. Again, glue may be applied over the entire surface 17' or in strips 19, as previously described.
Figs. 6 and 7 illustrates the formation of the bottom support platform 13 and it consists of similar blanks 22 and 23, provided either in individual form as shown in Figs. 6A and 6B, or interconnected together, as shown in Fig. 7. As herein shown, the difference between the top support platform 11 and the bottom support platform 13 is that the blanks 22 and 23 may be provided with the clearance holes 15 which extend through both blanks. Once the bottom support platform 13 is formed, in like manner as the top support 2 1 ~ 9 . i ~
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platform, the free ends 14 of the cylinders are received in the cylinder-receiving holes 24 formed in one of the blanks of the bottom support platform which also have glue on the bottom wall thereof.
The method of fabrication can also be modified wherein the cylinder-receiving holes 24 are formed after the two blanks 16 and 17, or 22 and 23, are glued together. The cylinder holes can then be embossed within one of the blanks to form cylinder-receiving cavities. In such a process it would then be necessary to again apply glue in the cylinder-receiving cavities at least about the periphery of the bottom wall of such cavities so as to bond the cylinders therein. However, the preferred method is to form the support platforms with blanks being formed in a single sheet of corrugated cardboard, as illustrated by Figs. 5, 6 and 7, and wherein the sheets are folded over one another.
- As shown in Figs. 4, 5 and 9, the corrugations 25 extend along the longitudinal axis of the pallet support platforms, and each layer of cardboard may consist of a plurality of corrugated layers depending on the strength required.
As shown in Figs. 4 to 8, the pallet may also have a plurality of aligned strap-receiving grooves 26 (see Fig. 9) formed in the outer peripheral edges 27 of the blanks. These grooves are defined by a pair of transverse slits 28 and a bendable panel section 29, disposed intermediate thereof between the slits 28 and a perforated line 30 extending therebetween spaced parallel and close to the peripheral edges 27.
Accordingly, when material needs to be strapped onto the pallet, a strap is positioned adjacent the panel section ~29 and the strap is tightened. As the strap tightens the panel section 29 will fold inwardly and the strap will be restricted from lateral movement by the groove formed by the collapsing of the panel. The opposed transverse slits 28 will then provide shoulders 31 to prevent lateral movement of the straps. Similar strap retraining grooves are also formed along the hinge line 21, as shown in Fig. 7.
It is pointed out that with the present method of construction of the recyclable cardboard pallet of the present invention the strength characteristics of the pallet can be varied depending on the requirement of the user. For example, the strength and thickness of the support platforms 11 and 13 may be varied by lo using different grade corrugated or solid cardboard.
As well, the cylinders 14 may be hollow cylinders or solid cylinders formed of solid cardboard material.
The configuration of the pallet can also be varied and it can, for example, be rectangular, square, oval or circular in outline. The average weight of pallets constructed in accordance with the present invention varies between about 12 lbs. to 20 lbs., and accordingly these are easily manipulatable by the user.
It also does not use any wooden planks, and accordingly there is no risk catching a splinter. Experiments have shown that such a pallet can also support loads of 5000 lbs. or more and accordingly the pallet has a variety of uses. The method of fabrication is also very fast utilizing entirely recyclable products. It is also conceivable that the platforms and the cylinders may be treated or coated to resist humidity, although the pallet of the present invention was conceived primarily for interior use.
It is within the ambit of the present invention to cover any other modifications, provided such modifications fall within the scope of the appended claims.
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Claims

1. A method of fabricating a paperboard pallet which is entirely recyclable, said method comprising:
(i) cutting from a cardboard material at least two support cardboard blanks to form a flat support platform;
(ii) cutting cylinder-receiving holes in one of said support blanks at predetermined locations;
(iii) applying glue to a surface of the other of said blanks;
(iv) superimposing said two blanks to bond them together by said surface having glue thereon;
(v) positioning a cylinder constructed of solid paperboard material in each of said cylinder-receiving holes in one of said support cardboard blanks to contact said surface of the other of said blanks on which glue has been applied to bond said cylinders into said holes, said cylinders having free ends which, when positioned on a support surface, maintains said support platform elevated therefrom.

2. A method as claimed in claim 1 wherein there is further provided the step of:
(vi) forming a second support platform in accordance with steps (i) to (iv) to form a bottom support platform for said pallet; and (vii) positioning said free ends of said cylinders in said cylinder-receiving holes of one of said support surface blanks of said second support platform.

3. A method as claimed in claim 2 wherein said step (ii), in the forming of said second support platform, comprises the additional step of cutting clearance holes at predetermined locations of said two support surface blanks whereby said bottom support platform provides clearance holes adapted to receive portions of wheels of lift dollies positioned under said pallet.

4. A method as claimed in claim 1 wherein there is further provided in said step (ii) slitting a plurality of closely spaced pairs of transverse slits at predetermined locations along outer peripheral edges of said two support surface blanks and providing a perforation line between said closely spaced pairs of transverse slits extending spaced from said peripheral edges to form bendable panel sections to receive strapping in peripheral grooved areas on the periphery of said support platform.

5. A method as claimed in claim 1 wherein said step (i) comprises cutting said two support cardboard blanks in a single sheet of cardboard material with said blanks interconnected side by side by a slit hinge line.

6. A method as claimed in claim 5 wherein said step (iv) comprises folding said blanks together along said slit hinge line to bond them together.

7. A method as claimed in claim 1 wherein said step (i) comprises cutting said blanks from corrugated cardboard material having at least two bonded corrugated layers therein.

8. A method of fabricating a paperboard pallet which is entirely recyclable, said method comprising:
(i) cutting from a cardboard material at least two support blanks to form a support platform;
(ii) applying glue to a surface of one of said blanks;

(iii) superimposing said two blanks to bond them together by said surface having glue thereon;
(iv) embossing cylinder-receiving cavities in one of said support surface blanks at predetermined locations;
(v) applying glue in said cylinder-receiving cavities;
(vi) positioning a cylinder constructed of solid paperboard material in each of said cylinder receiving cavities for bonding therein by said glue, said cylinders having free ends which, when positioned on a support surface, maintain said support platform elevated therefrom.

9. A method as claimed in claim 8 wherein there is further provided the step of:
(vii) forming a second support platform in accordance with steps (i) to (iv) to form a bottom support platform for said pallet;
(viii) applying glue in said cylinder-receiving cavities of said bottom support platform; and (ix) positioning said free ends of said cylinders in said cylinder-receiving cavities of said bottom support platform.

10. An entirely recyclable paperboard pallet comprising a flat support platform formed by two support blanks of corrugated cardboard folded together along a hinge line in superimposition and glued together, a bottom one of said blanks having a plurality of cylinder-receiving cavities formed therein at predetermined locations, a solid paperboard cylinder secured in each said cylinder-receiving cavity by glue to bond said cylinders thereto, said cylinders having free ends which, when positioned on a support surface, maintain said support platform elevated therefrom.

11. A pallet as claimed in claim 10 wherein a flat bottom support platform identical to said support platform receives said free ends of said cylinders in cylinder-receiving cavities also formed therein, said cylinder free ends being bonded by glue in said cylinder-receiving cavities of said bottom support platform, said bottom support platform having clearance holes therein t predetermined locations to provide clearance holes adapted to receive portions of wheels of lift dollies positioned under said pallet.

12. A pallet as claimed in claim 11 wherein said support platform is a top support platform, said top and bottom support platforms have a plurality of aligned strap-receiving grooves in outer peripheral edges thereof, said grooves being defined by a pair of transverse slits and a bendable panel intermediate thereof and defined between said slits and a perforation line extending therebetween and spaced parallel and close to said peripheral edges.