GB2276368A

GB2276368A - Palletised containers and pallets therefor

Info

Publication number: GB2276368A
Application number: GB9405999A
Authority: GB
Inventors: Raymond James Keys
Original assignee: Individual
Current assignee: Individual
Priority date: 1993-03-26
Filing date: 1994-03-25
Publication date: 1994-09-28
Also published as: AU5907994A; CA2119791A1; GB9405999D0

Abstract

A pallet for a container or case comprises a rectangular base having flaps (28) extending from two opposed sides thereof, and a plurality of stiffening means (24, 32) extending across the base, with the base being foldable about a line extending across the base, preferably centrally, between the two sides which have the flaps. This folding facilitates the filling of the pallet to a container (10) by interfitting of the pallet flaps (28) with flaps (14) on the bottom of the container. <IMAGE>

Description

PALLETISED CONTAINERS AND PALLETS THEREFOR This invention relates to palletised containers, and particularly to what are known as integrated case and pallet structures. It is also concerned with pallets for attachment to cases or containers.

The transportation of goods in containers or cases made for example from corrugated fibreboard material makes it desirable for the individual containers or cases to have their own integrated pallets, so that the units can readily be lifted by a fork lift truck for example. With an integrated case and pallet construction, the pallet remains with the container or case during transportation, thereby avoiding the need for a separate, conventional pallet.

GB-A-796695 describes a supporting pallet designed to be removably associated with a cardboard box. The pallet is attached to the bottom face of the box by having flaps insertable through the open bottom of the box so as to lie within the box structure. The pallet is a rigid component made from two sheets of corrugated cardboard with spacer members therebetween, thus preventing any folding of the basic pallet structure.

GB-A-1515730 describes a rigid pallet which again is attached to the bottom of a carton by having a flap which is insertable under flaps of the carton itself, thereby to hold the pallet in place.

GB-A-1601365 describes a pallet for attachment to a container, wherein the pallet comprises a first rigid sheet co-extensive with the base of the container and a second sheet which is foldable and is affixed to the first sheet, the folding action creating flaps by which the pallet can be removably attached to the container.

GB-A-2121003 again describes a combined carton and supporting pallet where the pallet has a base of the same size and form as the erected carton and has insertion flaps at the edges which tuck into the base of the carton.

GB-A-2128582 describes a pallet for an air freight container which is a one-piece base with opposed side flaps which extend up into the container where they are folded down and held in place.

GB-A-2150533 describes a foldable container but again it is adapted to be secured to a rigid pallet base.

It is one object of the present invention to provide an integrated case and pallet structure which can be readily assembled and which is strong and secure.

It is a further object of the invention to provide an integrated case and pallet structure where the provision of the pallet involves no additional stitching or glueing to the container or case.

It is yet a further object of the invention to design the structure such that the container or case can be delivered to an assembly point in a flat form, together with the pallet.

It is yet a further object to provide a pallet structure which can more readily be assembled to a case or container than with many of the known structures, particularly for large size pallets.

In accordance with one aspect of the present invention there is provided a palletised container comprising a container or case, and a pallet structure for attachment to the container or case, wherein the part of the pallet structure which is co-extensive with the container or case is foldable to facilitate the attachment of the pallet to the container or case.

In a preferred embodiment of the invention the pallet structure is foldable about a centre line.

Preferably, the pallet structure includes flaps which are arranged to interengage with flaps on the container or case to hold the pallet structure fixedly in position on the container or case.

Also in accordance with the invention there is provided a pallet for integration with a container or case, the pallet comprising a rectangular base having flaps extending from two opposed sides thereof, and a plurality of stiffening means extending across the base, with the base being foldable about a line extending across the base between the two sides which have said flaps.

In order that the invention may be more fully understood, a number of presently preferred embodiments in accordance with the invention will now be described by way of example and with reference to the accompanying drawings, in which: Fig. 1 is an illustration of the assembly of a first embodiment of pallet; Fig. 2 shows the pallet of Fig. 1 in assembled format; Fig. 3 shows the pallet of Fig. 2 folded about a centre line; Fig. 4 shows the pallet of Fig. 3 being presented to a case; Fig. 5 shows the pallet and case of Fig. 4 in a partially assembled form; Fig. 6 shows the final assembly of the case and pallet of Fig. 5; Fig. 7 shows the assembly of a second embodiment of pallet; Fig. 8 shows a further step in the assembly of the pallet of Fig. 7; Fig. 9 shows the pallet of Fig. 8 folded about a centre line and presented to a case;; Fig. 10 shows the pallet and case of Fig. 9 in a partially assembled form; Fig. 11 shows the case and pallet of Fig. 10 in the finally assembled form; Fig. 12 shows a locking device to secure the pallet and case in the assembled form; Figs. 13 to 16 illustrate steps in the assembly of a third embodiment of palletised container; Figs. 17 and 18 illustrate steps in the assembly of a fourth embodiment of palletised container; Figs. 19 to 22 illustrate steps in the assembly of a fifth embodiment of palletised container; Figs. 23 to 25 illustrate steps in the assembly of a first embodiment of free-standing pallet; Figs. 26 and 27 illustrate steps in the assembly of a second embodiment of free-standing pallet; Figs. 28 to 30 illustrate steps in the assembly of a third embodiment of free-standing pallet;; Figs. 31 to 33 illustrate steps in the assembly of a fourth embodiment of free-standing pallet; Fig. 34 illustrates a further step in the assembly of a palletised container; Fig. 35 shows the final assembly step in the making of a palletised container; Fig. 36 is a detail view showing the reverse folding of the board material from which the pallets are made; Figs. 37 to 42 illustrate steps in the assembly of a sixth embodiment of palletised container; Figs. 43 to 48 illustrate steps in the assembly of a seventh embodiment of palletised container; Fig. 49 is a plan view of the layout for a one-piece two way entry free-standing pallet; Fig. 50 shows the pallet of Fig. 49 when assembled; Fig. 51 is a plan view of the layout for a one-piece four way entry free-standing pallet; and Fig. 52 shows the pallet of Fig. 51 when assembled.

Referring first to Fig. 4, this shows a case/container which is to form part of the integrated case and pallet of the present invention. The case/container 10 is formed from at least one piece of foldable packaging material. The material from which the case is made may be for example a corrugated fibreboard material, such as triple-fluted fibreboard for particularly heavy duty cases or double-walled corrugated board for normal applications. The case has two opposed end walls 12, each with a top flap (not shown) and a bottom flap 14. The case also has two opposed sides 16, each with a top flap (not shown) and a bottom flap 18. The case is joined along the adjacent edges of one side and one end, as indicated at 20, for example by stitching or glueing or stitching and glueing.

The pallet part of the construction is shown in Fig. 1. The pallet is formed from at least three pieces of foldable packaging material. The preferred material for the pallet is a single or double-wall corrugated fibreboard. The first piece of foldable packaging material is indicated generally at 22. This consists of a rectangular sheet of board from which the four corners have been removed by a suitable cutting method, leaving two rectangular board areas 24 extending from opposed sides of the main board area.

These two projecting areas 24 are creased and/or scored across the corrugations to enable them each to be folded into a hollow box-shaped configuration which is then glued or stitched onto the main board area as indicated in Fig. 1 for the left hand portion 24.

Creases/scores 26 are made along the corrugations between the margins of the projecting portions 24 to form pallet flaps 28 which are arranged to be folded down and back under the pallet, as shown in Fig. 2. A centre crease/score 30 is provided across the corrugations across the full width of the first piece of material 22. This centre crease/score enables the pallet to fold about this centre line as illustrated in Fig. 3. Two further pieces of foldable packaging material 32 are each creased/scored across the corrugations to enable them to be folded into a hollow box shape configuration which is then glued or stitched together. These pieces 32 are then ready to be fixed to the main board area. Each piece 32 has a length which is equal to half the distance between the crease/score lines 26.As shown most clearly in Fig. 1, an imaginary centre line on one of the wider sides of each box-shaped piece 32 is positioned directly over the centre fold line 30. The pieces 32 are then glued or stitched over only half their respective areas onto the main board and on respective opposite sides of the centre fold line 30. In other words, the pieces 32 are stitched or glued onto the areas 34 which are indicated by cross hatching in Fig. 1. It is to be noted that the creases/scores 26 and 30 are in fact made on the reverse side of the sheet of material 22, i.e. on the underside as viewed in Fig. 1. It should also be noted that the portions 24 which are shown in Fig. 1 as being integral with the main sheet of material 22 could alternatively be formed as separate items, which are then stitched or glued to the main sheet.In this case each portion 24 would be creased/scored with four lines to make five sections which would fold into a hollow box-shaped configuration which would then be glued or stitched together before being fixed, again by glueing or stitching, to the margins of the main board 22.

To assemble the integrated case and pallet shown in Figs. 1 to 6, it is first necessary to assemble the case 10 from a flat form into its made-up form as shown in Fig. 4. The pallet, constructed as shown in Fig. 2, is folded about the centre line 30 as shown in Fig. 3. The pallet is then attached to the case by sliding the pallet down on to one of the bottom end flaps 14 of the case, as shown in Fig. 4. This procedure positions the bottom end flap 14 between the pallet flaps 28 and the pallet base. The next stage is to align the other end of the pallet with the other bottom end flap 14 of the case. This flap 14 is inserted between the flaps 28 of the pallet and the pallet base and is pushed until the pallet lies flat on the base of the case, as shown in Fig. 6.It is then only necessary to insert three bearers or struts 36 which are of equal length into the hollow box-shaped portions 24, 32 of the pallet. With the central bearer or strut 36 pushed through the two central box-shaped pieces 32 the pallet is firmly locked against folding and is secured to the case by the interengagement of the respective flaps 14 and 28.

Referring now to Figs. 7 to 12 there is shown an alternative embodiment of pallet for attachment to the case 10. Here the pallet is formed from one piece 40 of foldable packaging material. The preferred material for this construction is a sheet of single or double-wall corrugated fibreboard. Three parallel creases/scores 42a, 42b, 42c are provided across the corrugations towards each end of the sheet 40 to define pallet flaps 28 as in the first embodiment. In the second embodiment top runners 44 are placed on the sheet 40 as shown in Fig. 7. These runners are preferably of timber. The pallet flaps 28 fold back over the runners 31. As in the first embodiment, a central crease/score 30 is provided across the sheet 40 to enable the pallet to fold as shown in Fig. 9.

Beneath the sheet 40 are positioned a plurality of timber blocks 46 and 48, as shown most clearly in Fig. 8. The top runners 44 are nailed to the blocks 46 and 48 with the corrugated sheet 40 therebetween. The pallet is then turned over (see Fig.

8) and bottom runners 50 and 52 are then nailed on to the timber blocks 46, 48. It is to be noted that as the blocks 48 and the top runners 52 which are positioned on each side of the centre line 30 meet along the centre line, the dimensions of these blocks and runners are smaller than those of the outside blocks 46 and runners 50. When the pallet is folded as shown in Fig. 10 the centre blocks 48 and their runners 52 pivot apart, one on each side of the centre line 30.

To assemble the integrated case and pallet shown in Figs. 7 to 12, it is first necessary to assemble the case from a flat form into the made-up form as shown in Fig. 9. The pallet is folded as shown in Fig. 9. The pallet is then attached to the case 10 by sliding the pallet down on to one of the bottom end flaps 14 of the case. This again positions this flap between the pallet flaps 28 and the pallet base. Then, as shown in Fig. 10, the other bottom end flap 14 of the case is located in the pallet and the pallet is pushed down until it lies flat against the bottom of the case. The flange created by using the crease/score 42a is then pushed into the centre of the pallet to achieve the position as shown in Fig. 11. It is then a simple procedure to lock the pallet in place by nailing a locking tab 54 to the central blocks 48 as shown in Fig. 12.This is repeated on the other side of the pallet. The pallet is then firmly locked in place against folding and is integrated with the case.

The bearers or struts 36 shown in Fig. 6 are preferably of high-density polystyrene, although alternative materials may be used. For example, three timber blocks similar to the blocks 46 in the second embodiment, secured between top and bottom timber runners (similar to the runners 50) could be used.

Alternatively, a corrugated fibreboard sheet could be used, suitably scored and slotted and folded to form a block suitable for insertion into the hollow box-like receivers.

Reference is now made to the embodiment shown in Figs. 13 to 15. This illustrates the pallet construction. This shows a die cut pallet, i.e. a shape cut out of one sheet of board. The material which is preferably used is corrugated fibreboard, although any other suitable material can be used. This pallet, in contrast to those described earlier, is a double deck pallet with the strengthening bearers between the decks. The die cut board shape is produced with two flanges 110, on opposite sides of the deck 108 of the pallet. The deck 108 is divided by a fold line 116 which, as will be apparent hereinafter, enables the pallet to be folded about this fold line 116. In Fig.

13 the board is shown as having a number of fold lines and reverse fold lines 124 and slits 126. After the necessary scoring and slitting of the sheet of board, the sheet can be folded into the configuration shown in Fig. 14, by which process tubes 120 are created by reverse folding of the sheet material at 124. These tubes 120 receive bearers 118, one at each side of the pallet and one centrally. It is to be noted however that the central bearer 118 is not inserted into the pair of central tubes 120 until the pallet has been fitted to the case/container, thereby locking the pallet to the case/container, as shown in Figs. 34 and 35. The bearers can be manufactured from corrugated fibreboard, expanded polystyrene or any other suitable material.

In the assembly step shown in Fig. 14, after the necessary folding, the parts are glued together in the areas indicated at 112 and 114, illustrated by cross-hatching in the drawings. The deck 108 is secured to the glued areas 112 and 114 to create the pallet structure shown in Fig. 15.

As shown in Figs. 16, 34 and 35, the pallet is fitted to the case/container 10 by first folding it about the centre line 116, then fitting the depending portion over one of the flaps 14 of the case/container and thereafter fitting the other half of the pallet to the opposing flap 14. As mentioned above, fitting of the central bearer or strut 118 then locks the pallet in its flat state and also locks it to the case/container.

Referring now to Figs. 17 and 18, these show a modified shape for the pallet sheet. Here, the sheet has four separate flanges 110 and the deck areas 108 are positioned one at each end of the sheet. In this embodiment, after the necessary folding, glueing is only required at the zones 114 at the centre of the pallet, as compared with the greater glueing area necessary in the preceding embodiment. Again, the glued area is indicated by cross-hatching in Fig. 18. Because in this embodiment the top deck 108 is in two parts which come together at the centre, the central fold line 116 which permits the assembly of the pallet on the case/container extends across one of the deck areas 108, towards the outer margin thereof as shown in Fig.

17.

Figs. 19 to 22 show a further embodiment of pallet construction. This pallet has two flanges 110, and a single glueing area 112 (Fig. 20). Although this construction is similar to that shown in Figs. 13 to 15, less glueing is required as the top deck 108 is attached to the pair of centre tubes 120 by fitting tongues 128 into the centre tubes 120 at the points 130 shown in Fig. 20. These tongues 128 are held in place by the central bearer 118 when this is fitted. It may be preferable to use two central bearers, one fitted from each end.

Figs. 23 to 25 show an example of freestanding pallet. Its initial configuration is similar to that shown in Fig. 13, but without the flanges 110 and without the fold line 116. The pallet is assembled by folding and glueing at the zones 112 and 114 and can be used as an alternative to a timber pallet.

Figs. 26 and 27, which should be viewed in combination with Fig. 25 show a pallet board configuration which is similar to that shown in Fig.

17, but again without the flanges 110 and without the central fold line 116. Although this is similar to the pallet construction shown in Figs. 23 and 24, it folds differently and requires less glueing as the two parts 108 of the top deck come together in the centre.

Figs. 28 to 30 show yet another free-standing pallet. The configuration here is similar to that shown in Fig. 20, except that the central fold line 116 across the top deck 108 is not present and the flanges 110 are omitted.

Figs. 31 to 33 show a free-standing pallet construction which is similar to that shown in Figs. 26 and 27, except that here the deck areas 108 are provided each with two cut-outs 136. When the sheet is folded, as shown in Figs. 32 and 33, glueing areas 114 are exposed through the top deck 108. In this embodiment the glueing area consists of those exposed areas 114 and also the remainder of the deck 108, so that an additional sheet of board 138 can be glued (laminated) onto the deck area. This provides a freestanding pallet, as shown in Fig. 33, of superior strength and which can be used as an alternative to a timber pallet.

Reference is now made to Figs. 37 to 42 which show another embodiment of die cut pallet which is arranged to be folded for fitting to a case/container.

This design of pallet does not require any additional manufacturing process such as glueing or stitching, as it is self-locking. It is a single deck pallet. The material used is preferably corrugated fibreboard, although any other suitable material can be used. The general configuration of the pallet is best shown in Figs. 37 and 38. The sheet includes four separate flanges 140, which are used as the means for attaching the pallet to the case/container 10. Slitting lines are indicated at 142 and fold/score lines at 143. Two cut-outs 141 are provided in the sheet, one towards each end of the blank. These are rectangular cut-outs, positioned between the fold lines 141. Reverse folding of scores is effected at the positions indicated at 145. This is shown more clearly in Fig. 39.

Additional reverse folding of scores is effected at 150.

The pallet is assembled by folding the board along the score lines 143, thus creating two outer tubes 144 which are locked by reverse folding of the scores at 145. Bearers 146 are then inserted into the outer tubes 144. The centre tube (in three sections) is created by folding of the score lines 149. At this stage the pallet is presented to the case/container as shown in Fig. 40. The pallet is then attached to the case/container as shown in Fig. 41. When the pallet lies flat on the case/container as shown in Fig. 42, the centre tube 148 is locked by reverse folding of the scores at 150. The central bearer 146 can then be inserted into the centre tube 148 to secure the pallet to the case/container.

Figs. 43 to 48 show a two-piece die cut pallet. A shape cut out of one sheet of board makes one half of the pallet, and each half of the pallet is identical to the other. As in the preceding embodiment, this pallet does not require any additional manufacturing process such as glueing or stitching, as it is self-locking. Each half of the pallet is fitted separately to the case/container 10, as shown most clearly in Fig. 46, and the two halves of the pallet come together at the centre before being locked together by a central bearer 182 (Fig. 48).

The configuration of each pallet half is shown in Fig. 43. The two flanges are indicated at 170. Slits are indicated at 174 and fold lines at 176.

Two cut-outs 172 are provided, one in each foldable end portion of the sheet. Score lines which are reverse folded are indicated at 180. The bearers are indicated at 182 and fit into tubes 178, 184. The central tube 184 is formed in two sections, one associated with each pallet half. As before, the flanges 170 are used as the means to attach each half of the pallet to the case/container 10. The pallet is assembled by folding the board along the score lines 176, to create two tubes, one 178 which is the full width of the case/container and the other 184 which is half the width of the case/container. These tubes are locked by reverse folding of the scores at 180 (Fig. 45).

Bearers 182 are then inserted into the tubes 178. At this stage each half of the pallet is presented to the case/container as shown in Fig. 46. The pallet is then attached to the case/container as shown in Fig. 47, and when the pallet lies flat on the case/container as shown in Fig. 48 the two half width tubes 184 will be in alignment and enable the central bearer 182 to be inserted to secure the pallet to the case/container.

Fig. 36 shows in more detail the method of reverse folding along a score line, a feature which is applicable to each of the embodiments described above.

Fig. 49 shows the layout of another one-piece die-cut two way entry pallet. The deck area is indicated at 208, slits at 226 and reverse score lines at 224. An optional score line is indicated at 230.

The pallet, in partly assembled form, is shown in Fig.

50. The assembly of the pallet is achieved simply by folding and glueing of various areas.

Figs. 51 and 52 show a broadly similar pallet but designed for four way entry instead of two way entry. Here, the blank is provided additionally with six cut-outs 232 which, when the pallet is assembled, provide the further two entry ways.

The layouts of Figs. 49 to 52 can alternatively be produced from two pieces of board, if required.

Claims

CLAIMS:

1. A palletised container comprising a container or case, and a pallet structure for attachment to the container or case, wherein the part of the pallet structure which is co-extensive with the container or case is foldable to facilitate the attachment of the pallet to the container or case.

2. A palletised container according to claim 1, in which the pallet structure is foldable about a centre line.

3. A palletised container according to claim 1 or 2, in which the pallet structure includes flaps which are arranged to interengage with flaps on the container or case to hold the pallet structure fixedly in position on the container or case.

4. A pallet for integration with a container or case, the pallet comprising a rectangular base having flaps extending from two opposed sides thereof, and a plurality of stiffening means extending across the base, with the base being foldable about a line extending across the base between the two sides which have said flaps.

5. A pallet according to claim 4, in which said fold line is midway across the base.

6. A pallet according to claim 4 or 5, in which stiffening means are provided along the fold line and at each side of the base which is parallel to the fold line.

7. A pallet according to claim 4, 5 or 6, in which the stiffening means along the fold line is in two parts, each part extending over one half the distance between the flaps and each part overlapping the fold line along its length, with the two parts being fixed to the base on respective opposite sides of the fold line only.

8. A pallet according to any of claims 4 to 7, in which each stiffening means comprises a tube of folded material with a removable bearer therein.

9. A pallet according to any of claims 4 to 8, in which the flaps when folded over the base almost meet across the centre of the base.

10. A pallet according to any of claims 4 to 9, which has an upper deck and a lower deck with said stiffening means therebetween.

11. A pallet according to claim 8, in which said tubes are formed by a reverse folding of the material of the pallet.

12. A pallet for integration with a container or case, the pallet comprising two parts each attachable to the container or case, wherein each part comprises a base having flaps extending from two opposed sides thereof, the two parts being respectively attachable to the container or case by said flaps and being pivotable into abutting engagement when folded flush against the container or case, and a plurality of stiffening means extending across the base and linking said two parts.

13.1A pallet made from an elongate, generally rectangular blank of material foldable along lines across its width and having slots therein parallel to its length, the folding of the blank generating a pallet having top and bottom decks with tubes of folded blank material therebetween to receive removable bearers.

14. A pallet according to claim 13, in which the bottom deck is in two parts foldable into contact across the centre of the pallet.

15. A pallet substantially as hereinbefore described with reference to any of the Figures of the accompanying drawings.

16. A palletised container substantially as hereinbefore described with reference to any of the Figures of the accompanying drawings.