GB2624146A

GB2624146A - Structure, kit of parts, and method

Info

Publication number: GB2624146A
Application number: GB2208619.3A
Authority: GB
Inventors: Macgillivray Patricia
Original assignee: Corridoor Ltd
Current assignee: Corridoor Ltd
Priority date: 2022-06-13
Filing date: 2022-06-13
Publication date: 2024-05-15
Also published as: GB202208619D0

Abstract

The first sub-structure 110 comprises an array of first walls 112. The first sub-structure 110 15 comprises a first surface 114. The first walls 112 are arranged to project away from the first surface 114. The first walls 112 comprises an arrangement of slots 116 for locating second walls. The second sub-structure 120 comprises an array of second walls 122. The second sub-structure 120 comprises a second surface 124. The second walls 122 are arranged to project away from the second surface 124. When the structure is assembled, the second walls 122 are located in the slots 116 of the first walls 112. Locating the second walls 122 in the slots 116 of the first wall 112, one or more cells 130 are defined between two of the first walls 112, two of the second walls 124, the first surface 114 and the second surface 124. The first 114 and second 124 surfaces may define outermost surfaces of the structure. The cells may be quadrilateral, rectangular, or square in cross section. The structure may comprise a pallet. Also disclosed is a kit of parts, and corresponding method.

Description

STRUCTURE, KIT OF PARTS, AND METHOD The present invention relates generally to a structure, to a kit of parts of a structure, and a method of manufacture of a structure.

Background

It is known to form structures from sheet material or comprising sheet-like portions. In one example, it is known to provide a structure that includes a profiled and/or formed structure (e.g. having a corrugation or undulation, such as a wave-like form). In another example, it is known to provide a structure that includes an array of honeycomb cells, formed by affixing planar strips of material at specific locations and subsequently separating the strips to form the cells.

In the art it is advantageous to use a variety of crush and compression tests to quantify the strength of such structures. One commonly used test is known as the "flat crush test". The test is, essentially, a measure of the load bearing capability of the structure to loads acting perpendicular to a surface of the structure or board.

Whilst both corrugated and honeycomb structures may exhibit enhanced ability to withstand a force applied in one particular direction, under the application of a force in another direction they may be no stronger than the sheet from which they are formed.

Existing structures and manufacturing approaches do not strike a balance between manufacturing cost, efficiency and complexity, versus the performance of the structure that is manufactured.

It is an object of the present invention to provide an improved structure, kit of parts, system for manufacturing a structure, and/or method and/or to address one or more of the problems discussed above, or discussed elsewhere, or to at least provide an alternative structure, structure formation apparatus and method.

Summary

According to the present invention there is provided an apparatus and method as set forth in the appended claims. Other features of the invention will be apparent from the dependent claims, and the description which follows.

According to a first aspect of the present invention, there is provided a structure comprising: a first sub-structure comprising: an array of first walls; a first surface, the first walls arranged to project away from the first surface, the first walls comprising an arrangement of slots for locating second walls therein; and a second sub-structure comprising: an array of second walls; a second surface, the second walls arranged to project away from the second surface, wherein the second walls are located in the arrangement of slots of the first walls, thereby to form one or more cells between: two of the first walls; two of the second walls; a region of the first surface; and a region of the second surface.

In one example, in the first sub-structure: the first walls extend in a first axis, the array extends in a second axis, and the first walls are arranged to project away from the first surface in a third axis, and, in the second sub-structure: the second walls extend in the second axis, the array extends in the first axis, and the second walls are arranged to project away from the second surface in the third axis.

In one example, the first axis, second axis, and third axis are mutually orthogonal axes.

In one example, the first surface is comprised in a first base defining an outermost surface of the first sub-structure and/or the second surface is comprised in a second base defining an outermost surface of the second sub-structure.

In one example, the first surface and/or second surface comprises a plurality of connecting members, the connecting members arranged to connect adjacent walls of the first sub-structure and/or second sub-structure.

In one example, the connecting members and first walls of the first sub-structure and/or the connecting members and second walls of the second sub-structure are integrally formed.

In one example, the connecting members and first walls of the first sub-structure and/or the connecting members and second walls of the second sub-structure are formed from a single piece of sheet material.

In one example, the connecting members and first walls of the first sub-structure and/or the connecting members and second walls of the second sub-structure are folded from a single piece of sheet material.

In one example, one or more of the second walls are located in a series of slots provided in the first walls.

In one example, free edges of the first walls contact the second surface.

In one example, the dimension of the first walls in the third axis and the dimension of the second walls in the third axis are the same, the slots extend from free edges of the first walls to the first surface, and the free edges of the second walls contact the first surface.

In one example, the cells have a quadrilateral cross-section, or quadrilateral profile.

In one example, the cells have a rectangular cross-section, or rectangular profile.

In one example, the cells have a square cross-section, or square profile. In one example, the structure is a board or a pallet component.

According to a second aspect of the present invention, there is provided a kit of parts of a structure comprising: a first sub-structure comprising: an array of first walls; a first surface, the first walls arranged to project away from the first surface, the first walls comprising an arrangement of slots for locating second walls therein; and a second sub-structure comprising: an array of second walls; a second surface, the second walls arranged to project away from the second surface, the second walls arranged to be locatable in the arrangement of slots of the first walls, thereby to form one or more cells between: two of the first walls; two of the second walls; a region of the first surface; and a region of the second surface.

In one example, the structure is a board or a pallet component.

According to a third aspect of the present invention, there is provided a pallet comprising a structure according to the first aspect of the present invention.

In one example, the structure is a board or a pallet component.

According to a fourth aspect of the present invention, there is provided a method of manufacture of the structure according to the first aspect comprising: providing a first substructure comprising: an array of first walls; a first surface, the first walls arranged to project away from the first surface, the first walls comprising an arrangement of slots for locating second walls therein; providing a second sub-structure comprising: an array of second walls; a second surface, the second walls arranged to project away from the second surface; and locating the second walls in the arrangement of slots of the first walls, thereby to form one or more cells between: two of the first walls; two of the second walls; a region of the first surface; and a region of the second surface.

In one example, the method comprises forming the first sub-structure and/or second sub-structure by pleating a sheet material, thereby to form the walls of the sub-structure.

In one example, in forming the first sub-structure, the method comprising providing slots in the first walls, or, alternatively, providing slots in the sheet material prior to pleating.

According to a fifth aspect of the present invention, there is provided a system for manufacturing the structure according to the first aspect of the present invention. The system comprises a first apparatus for manufacturing a first sub-structure and/or a second apparatus for manufacturing a second sub-structure.

In one example, the first apparatus comprises a former assembly. In one example, the first apparatus comprises a slotting assembly.

In one example, the second apparatus comprises a former assembly.

In one example, the system further comprises a locating assembly configured to locate the second walls of the second sub-structure in the arrangement of slots of the first walls.

It will of course be appreciated that features described in relation to one aspect of the present invention may be incorporated into other aspects of the present invention. For example, the method of the fourth aspect of the invention may incorporate any of the features described with reference to the structure of the first aspect, and/or the kit of the second aspect, and/or the system of the fifth aspect, and vice versa.

Other preferred and advantageous features of the invention will be apparent from the following description.

Brief Description of the Drawings

For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example only, to the accompanying diagrammatic drawings in which: Figure 1 shows an exploded view of a structure comprising a first sub-structure and a second sub-structure; Figure 2 shows a plan view cross-section through a structure; Figure 3 shows formation of a first sub-structure; Figure 4 shows formation of a second sub-structure; Figure 5 shows a schematic view of a system for manufacturing a structure; and Figure 6 shows general methodology principles.

Detailed Description

In the description herein, a structure comprising a first sub-structure and second sub-structure is described. The invention is not limited to forming the structure, first sub-structure and/or second sub-structure from any material in particular. However, in particularly advantageous embodiments, the first sub-structure and second sub-structure are formed from paper (particularly kraft paper) or card, which may be provided as sheet material. This may be particularly advantageous where walls are to be formed by pleating the paper or card sheet material. Despite being formed from paper or card, the structure according to the present invention is strong and capable of withstanding heavy loads, by virtue of the construction described herein.

Referring to Figure 1, a structure 100 is shown in exploded view. The structure 100 comprises a first sub-structure 110 and a second sub-structure 120. In this exemplary embodiment, the first sub-structure 110 and second sub-structure 120 are separately formed (e.g., distinct) substructures. That is, the first sub-structure 110 and second sub-structures may be formed separately, possibly at different locations or in different manufacturing facilities, and may be formed by employing different apparatus. The structure 100 is a "two-part" structure.

Subsequent to their manufacture, the first sub-structure 110 and second sub-structure 120 may be provided as pads of a kit comprising the first sub-structure 110 and the second substructure 120. The pads may then be assembled to form the structure 100.

The first sub-structure 110 comprises an array of first walls 112. The first sub-structure 110 comprises a first surface 114. The first walls 112 are arranged to project away from the first surface 114. The first walls 112 comprises an arrangement of slots 116. The arrangement of slots 116 are for locating second walls (as described in greater detail below) therein.

The second sub-structure 120 comprises an array of second walls 122. The second substructure 120 comprises a second surface 124. The second walls 122 are arranged to project away from the second surface 124.

When the structure is constructed or assembled, the second walls 122 are located in the arrangement of slots 116 of the first walls 112. By locating the second walls 122 in the arrangement of slots 116 of the first walls 112, one or more cells 130 are thereby formed. This is achieved by inserting the second walls 122 into the slots 116 of the first walls 112, by bringing the first sub-structure 110 and second sub-structure 120 together On the vertical direction, as shown in the figure). Adhesive (such as starch adhesive) may be applied to the first sub-structure 110 and/or second sub-structure 120, at or in the region of the slots 116, or at the free edges of walls (described below) so as to adhere the first sub-structure 110 and second sub-structure 120 together in assembled form.

Referring to Figure 2, cells 130 are illustrated in plan view, in cross-section through the structure 100. The second surface 124 (which, when present, covers an outer surface of the structure 100) is not visible, to expose the inner cell structure. The cells 130 are formed between: two of the first walls 112 (e.g., 112a, 112b); two of the second walls 122 (e.g., 122a, 122b); a region of the first surface 114 (e.g., 114a); and a region of the second surface 124.

That is, in this exemplary embodiment, the cells 130 are "closed cells", in that the volume of the cell is enclosed by the walls 112, 122 and surfaces 114, 124.

By this construction, a structure 100 is formed (or is formable by the provision of first substructure 110 and second sub-structure 120) having an arrangement of interlocking first walls 112 and second walls 122. Advantageously, the structure 100 has beam strength in two perpendicular axes. Beam strength is a term used to refer to strength or rigidity along a line. That is, the array of first walls 112 provide beam strength, or rigidity, in a first axis 132, whilst the array of second walls 122 provide beam strength, or rigidity, in a second axis 134 which is perpendicular to the first axis 132. The structure 100 thus exhibits good fiat-crush test performance. Furthermore, the structure 100 has improved resistance to shear forces.

The second walls 122 being "located in" the arrangement of slots 116 may otherwise be described as the second walls 122 being received in, or inserted into, the slots 116. Additionally, it will be appreciated the second walls 122 extend into the slots 116 and interconnect, or "cooperate", to provide structural strength.

Referring back to Figure 1, in the first sub-structure 110, the first walls 112 extend in the first axis 132, the array of walls 112 extends in the second axis 134, and the first walls 112 are arranged to project away from the first surface 114 in a third axis 136. In the second substructure 120, the second walls 122 extend in the second axis 134, the array of second walls 122 extends in the first axis 132, and the second walls 122 are arranged to project away from the second surface 124 in the third axis 136.

Such an arrangement facilitates a construction wherein the walls 112, 122 are cross oriented to provide beam strength in a plurality of directions, whilst the walls 122, 122 are arranged to interlock with one another.

The term "array of walls" may be used to refer to an ordered series or arrangement of walls, in a direction other than the direction in which the walls themselves extend. The "array" may otherwise be referred to as a "set" of walls. The array of walls may be an array of regularly or irregularly spaced walls. The walls arranged to "project away" from the surface 114, 124 may mean that the walls are extending from the respective surface, either upwardly or downwardly. Importantly, the walls extend in opposite directions (vertically upward or vertically downward) such that they can be interlocked or interlinked by the insertion of walls 122 into slots 116.

The first axis 132, second axis 134, and third axis 136 are mutually orthogonal axes. In this way, a regular arrangement of cells can be formed, leading to a regular structure configuration, including regular cell configuration. This may simplify manufacture. The length of the first walls 112 and second walls 122 thereby extend in perpendicular directions. This leads to an interlocking construction when the second walls 122 are located in the slots 116 of the first walls 112.

The first surface 114 is comprised in a first base 140 defining an outermost surface of the first sub-structure 110. The second surface 124 is comprised in a second base 150 defining an outermost surface of the second substructure 120. The first base 140 is provided in a first plane, and the second base 150 is provided in a second plane. The term "base" is used to refer to the general planar arrangement from which the walls extend. The base may be formed from a single piece of material, or from multiple pieces of material. When formed in the structure 100, the first base 140 forms a first outermost surface of the structure 100, and the second base 150 forms a second outermost surface of the structure 100. In the structure 100, the first base 140 may provide the lowermost, or bottom, surface of the structure 100. In the structure 100, the second base 150 may provide the uppermost, or top, surface of the structure 100.

The first base 140 comprises a plurality of connecting members 142. The second base 150 comprises a plurality of connecting members 152. Specifically, the first surface 114 comprises the plurality of connecting members 142, and the second surface 124 comprises the plurality of connecting members 152. The connecting members 142 are arranged to connect adjacent walls 112 of the first sub-structure 110. The connecting members 152 are arranged to connect adjacent walls 122 of the second sub-structure 120.

In this way, the walls 112, 122 can be mutually connected and provided as arrays by being connected by the connecting members 142, 152. Furthermore, the bases 140, 150, or similarly the first and second surfaces 114, 124, need not be a single surface, but instead can be provided by connecting members. This may facilitate a multi-piece construction, or, in a highly advantageous embodiment, the bases 140,150 / first and second surface 114, 124 can be provided by folding sheet material.

In a highly advantageous embodiment, as shown in Figure 1, the first sub-structure 110 is formed by pleating a first sheet of material, and the second sub-structure 120 is formed by pleating a second sheet of material. Each sheet of material is pleated to provide the above described array of walls from which the walls project. Between the pleats (defining walls), connecting members are provided which connect adjacent walls. Ultimately, it will be understood that the walls being connected is by virtue of the provision of a single sheet of material being used to form the walls and connecting members. That is, each of the first substructure 110 and second sub-structure 120 are preferably formed by pleating a single sheet of material. It will be appreciated that it is therefore possible to describe the first surface 114 and second surface 124, and first base 140 and second base 150, as being "made up of' connecting members 142, 152.

Specifically, the connecting members 142 and first walls 112 of the first sub-structure 110, and/or the connecting members 152 and second walls 122 of the second sub-structure 120 are integrally formed. In this highly advantageous embodiment, the first and second substructure 110, 120 are formed from a single piece of sheet material, and most preferably folded/ pleated from a single piece of sheet material.

Advantageously, in this way material strength is retained, as the walls and connecting members are formed from a single piece. Multiple components are not required to be connected or adhered to one another to form the above-described sub-structures 110, 120. Furthermore, the sub-structures can be formed at high throughput speeds by manipulation of single sheets of material.

Referring to Figures 3, pleating of sheet material to form the first sub-structure 110 is shown. Fold lines 162 are provided to assist pleating of the material. The pleats form the first walls 112, whilst the spacing between the pleats form the connecting members 142. The first walls 112 project upwardly away from the connecting members 142. The slots are not yet present in the first sub-structure illustrated in Figure 3.

Referring to Figure 4, pleating of sheet material to form the second sub-structure 120 is shown. Fold lines 172 are provided to assist pleating of the material. The pleats form the second walls 122, whilst the spacing between the pleats form the connecting members 152. The second walls 122 project downwardly away from the connecting members 152.

Referring back to Figure 1, one or more of the second walls 122 are located in a series of slots 118 provided in the first walls 112. That is, a series of slots 118a, 118b is a series of slots aligned in the second axis 134 (e.g., laterally aligned), such that a second wall 122 (which extends in the second axis 134) can be received in said series of slots 118. That is, the series of slots 118 are provided by correspondingly arranged (e.g., laterally aligned) slots in a plurality of first walls 112. The series of slots 118 may be a linearly aligned series. The first walls 112 each comprise a set of regularly spaced apart slots, such that corresponding slots 116 of the first walls 112 form the series of slots 118. That is, one slot of the series of slots 118 is provided in each of the first walls 112.

In this way, a second wall 122 having a planar form can be located in said series of slots 118.

Advantageously, lateral beam strength can thereby be provided, by interlocking a second wall 122 with a first wall 112 by insertion into a series of slots 118.

The slots 116 extend from a free edge 119 of the first walls 112 to the first surface 114. That is, the slots 116 are provided through the entire height of the first walls 112. The slots 116 are formed by cutting or slitting the first walls 112 from the free edge 119 to the first surface 114. In the formed structure, the free edges 119 of the first walls 112 contact the second surface 124 of the second sub-structure 120. In this way, support is provided to the second surface 124 by the first walls 112. A structure having improved flat-crush test performance is thereby provided, as the structure 100 is resistant to load at the uppermost surface.

The dimension of the first walls 112 in the third axis 136 and the dimension of the second walls 122 in the third axis 136 are the same. In other words, the first walls 112 and second walls 122 have equivalent height. The slots 116 extend from the free edges 119 of the first walls 112 to the first surface 114. The free edges 129 of the second walls 122 contact the first surface 114.

Advantageously, by the free edges 119 of the first walls 112 contacting the second surface 124, and the free edges of the second walls 122 contacting the first surface 114, the structure 100 is resistant to compression forces applied from above and below the structure 100, i.e., at the first base 140 and second base 150 of the first and second sub-structures 110, 120. Beam strength in the first axis 132 and second axis 134 (i.e., in two perpendicular axes) is also provided.

Whilst the examples shown and described herein comprise slots 116 provided in the first walls 112 only, it will be appreciated that in other embodiments consistent with the present invention, an arrangement of slots may be provided in the second walls 122. The slots in the second walls 112 are for locating first walls 112 therein. In this case, one or more of the first walls 112 may not comprise a slot at a corresponding location, but instead the first walls 112 may be locatable in the slot of the second wall 122. In other words, rather than the first walls 112 comprising all slots 116 and the second walls 122 being for locating/receiving in the slots 116, the second walls 122 may comprise an arrangement of slots, in addition to the slots in the first walls 112, such that the first walls 112 may be received in the slots of the second walls 122 at the location(s) of the slots in the second walls 122, and the second walls 122 may be received in the slots 116 of the first walls 112 at the location(s) of the slots 116 in the first walls 112. An interlocking construction is thereby provided.

Additionally, whilst the examples shown and described herein comprise slots 116 extending from the free edges 119 of the first walls 112 entirely through the height of the first walls 112 to the first surface 114, the slots 116 need not necessarily have this construction. Instead, the slots 116 may extend from the free edges 119 of the first walls 112, but not to the first surface 114, and a corresponding slot may be provided in the second wall 122 extending toward the second surface 124. In this way, the first wall 112 may partially receive the second wall 122 and the second wall 122 may partially receive the first wall 112. In other words, corresponding slots may be provided in first wall and second wall, for engaging with one another, rather than slots being provided in only the first walls 112 for receiving the second walls 122. In an example, the heights (i.e., dimension in the third axis 136) of the first walls 112 and second walls 122 may be the same, and the first walls 112 and second walls 122 each comprise corresponding slots for engaging with one another which each have a length equal to half the height of the walls. In this way, engaging the slots results in a structure where the free edges 129 of the second walls 122 contact the first surface 114 and the free edges 119 of the first walls 112 contact the second surface 124.

As illustrated in Figures 1 and 2, in a plane parallel to the first axis 132 and second axis 134, the cells 130 have a quadrilateral cross section. Specifically, the cells 130 have a rectangular cross section. More specifically, the cells 130 have a square cross section. This advantageously results in a simplified construction of the structure 100 having beam strength in two dimensions. The aforementioned "cross section" may otherwise be referred to as a cell "profile". Such cross sections are particularly advantageous as beam strength is provided in multiple directions, particularly in perpendicular directions. In this way, the structure 100 is resistant to forces applied in multiple directions.

A structure 100 is described above. The structure 100 comprises a first sub-structure 110 and a second sub-structure 120. The first sub-structure 110 and second sub-structure 120 may be provided as a kit of parts of a structure 100. That is, a kit of parts of a structure 100 comprises a first sub-structure 110 and a second sub-structure 120. The structure 100, first sub-structure 110 and second sub-structure 120 are as described herein. That is, the first sub-structure 110 comprises an array of first walls 112; a first surface 114, the first walls 112 arranged to project away from the first surface 114, the first walls 112 comprising an arrangement of slots 116 for locating second walls 122 therein. The second sub-structure 120 comprises an array of second walls 122; a second surface 124, the second walls 122 arranged to project away from the second surface 124, the second walls 122 arranged to be locatable in the arrangement of slots 116 of the first walls 112, thereby to form one or more cells 130 between: two of the first walls 112; two of the second walls 122; a region of the first surface 114; and a region of the second surface 124.

In assembling the kit to form the structure 100, the second walls 122 are located in the arrangement of slots 116 of the first walls 112 by inserting the second walls 122 into the slots 116. The second walls 122 may be inserted into the arrangement of slots 116 of the first walls 112 by positioning (e.g., holding) the second sub-structure 120 above the first sub-structure 110 and bringing the sub-structures 110, 120 together in a downward/upward motion, thereby engaging the second walls 122 with said slots 116. Specifically, each one of the second walls 122 is brought into engagement with a respective series of slots 118, such that in the assembled structure 100, each second wall 122 is located in a respective series of slots 118. Each second wall 122 is inserted into a series of slots 118. Consecutive second walls 122 are inserted into consecutive series of slots 118. A plurality of cells 130 are thereby formed.

Advantageously, by such a construction an arrangement of cells 130 is formed, whereby walls 112, 122 interlock with each other and provide structural strength and rigidity.

One or more liners, or "liner layers", may be applied to one or both of the first base 140 and second base 150 as outermost (i.e., uppermost or lowermost) layers. Such liner layers may be advantageous in increasing the overall strength of the structure 100. For example, the liner layers may act to retain the pleated configuration of the sub-structures 110, 120. Furthermore, the liner layers may allow for the printing of information, e.g., branding, thereon. The one or more liners may be applied subsequent to assembly of the structure 100, or applied to the substructures 110, 120 prior to assembly to form the structure 100.

In a highly advantageous embodiment, the structure 100 is incorporated in, or used to manufacture, a pallet. A pallet (also called a skid) is a flat transport structure, which supports goods in a stable fashion while being lifted by a forklift, a pallet jack, a front loader, a jacking device, or an erect crane. A pallet is the structural foundation of a unit load, which allows handling and storage efficiencies. The structure 100 may advantageously be incorporated in a pallet as a pallet cover (an upper planar covering structure). The structure 100 is capable of withstanding high loads, and thus protecting the pallet from damage. In general, the structure 100 may be provided as a board, or as a pallet component.

Referring to Figure 5, a system 500 for manufacturing the structure 100 is shown. The system 500 comprises a first apparatus 510 for manufacturing the first sub-structure 110. The system 500 comprises a second apparatus 520 for manufacturing the second sub-structure 120.

The first apparatus 510 comprises a former assembly, for forming the first sub-structure 110. In a preferred embodiment, the former assembly is configured to pleat sheet material, in a spaced apart manner, so as to provide the array of first walls 112 (defined by the pleats) and the first surface 114 (defined by connecting members 142, between the spaced apart pleats).

The first apparatus 510 further comprises a slotting assembly. The slotting assembly is configured to provide the arrangement of slots 116 in the first walls 112. The slotting assembly may provide the slots 116 by cutting or scoring the first walls 112. Alternatively, the slotting assembly may precede the former assembly, such that the slots are formed in the sheet material prior to forming to form first walls 112.

The second apparatus 520 comprises a former assembly, for forming the second sub-structure 120. In a preferred embodiment, the former assembly is configured to pleat sheet material, in a spaced apart manner, so as to provide an array of second walls 122 (defined by the pleats) and a second surface 124 (defined by connecting members, between the spaced apart pleats).

The system 500 further comprises a locating assembly 530. The locating assembly 530 is 35 configured to locate the second walls 122 of the second sub-structure 120 in the arrangement of slots 116 of the first walls 112. In this way, the structure 100 is formed from the first substructure 110 and the second sub-structure 120. The locating assembly 530 may further comprise an applicator assembly. The applicator assembly is configured to apply an adhesive (such as starch adhesive) to the first sub-structure 110 and/or second sub-structure, preferably at the slots 116 or at the free edges of the sub-structures 110, 120, thereby to join or adhere the sub-structures 110, 120 in-place.

Referring to Figure 6, a method of manufacture of the structure 100 is shown schematically. Step 610 comprises providing a first sub-structure comprising: an array of first walls; a first surface, the first walls arranged to project away from the first surface, the first walls comprising an arrangement of slots for locating second walls therein. Step 620 comprises providing a second sub-structure comprising: an array of second walls; a second surface, the second walls arranged to project away from the second surface. Step 630 comprises locating the second walls in the arrangement of slots of the first walls, thereby to form one or more cells between: two of the first walls; two of the second walls; a region of the first surface; and a region of the second surface.

Optional Step 640 comprises forming the first sub-structure 110 and/or second sub-structure 120 by pleating a sheet material, thereby to form the walls 112, 122 of the sub-structure 110, 120; and, optionally, in forming the first sub-structure 110, the method comprising providing slots 116 in the first walls 112, or, alternatively, providing slots 116 in the sheet material prior to pleating.

Although a few preferred embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications might be made without departing from the scope of the invention, as defined in the appended claims.

Although the example embodiments have been described with reference to the components, modules and units discussed herein, such functional elements may be combined into fewer elements or separated into additional elements. Various combinations of optional features have been described herein, and it will be appreciated that described features may be combined in any suitable combination. In particular, the features of any one example embodiment may be combined with features of any other embodiment, as appropriate, except where such combinations are mutually exclusive. Throughout this specification, the term "comprising" or "comprises" means including the component(s) specified but not to the exclusion of the presence of others.

Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

Claims A structure comprising: a first sub-structure comprising: an array of first walls; a first surface, the first walls arranged to project away from the first surface, the first walls comprising an arrangement of slots for locating second walls therein; and a second sub-structure comprising: an array of second walls; a second surface, the second walls arranged to project away from the second surface, wherein the second walls are located in the arrangement of slots of the first walls, thereby to form one or more cells between: two of the first walls; two of the second walls; a region of the first surface; and a region of the second surface.
2 The structure according to claim 1 wherein, in the first sub-structure: the first walls extend in a first axis, the array extends in a second axis, and the first walls are arranged to project away from the first surface in a third axis, and, in the second sub-structure: the second walls extend in the second axis, the array extends in the first axis, and the second walls are arranged to project away from the second surface in the third axis.
3. The structure according to claim 2 wherein the first axis, second axis, and third axis are mutually orthogonal axes.
4 The structure according to any one of the preceding claims, wherein the first surface is comprised in a first base defining an outermost surface of the first sub-structure and/or the second surface is comprised in a second base defining an outermost surface of the second sub-structure.
5. The structure according to any one of the preceding claims, wherein the first surface and/or second surface comprises a plurality of connecting members, the connecting members arranged to connect adjacent walls of the first sub-structure and/or second sub-structure.
6 The structure according to claim 5, wherein the connecting members and first walls of the first sub-structure and/or the connecting members and second walls of the second sub-structure are integrally formed, preferably from a single piece of sheet material, most preferably folded from a single piece of sheet material.
7 The structure according to any one of the preceding claims, wherein one or more of the second walls are located in a series of slots provided in the first walls.
8 The structure according to any one of the preceding claims, wherein free edges of the first walls contact the second surface.
9. The structure according to claim 8, wherein the dimension of the first walls in the third axis and the dimension of the second walls in the third axis are the same, the slots extend from free edges of the first walls to the first surface, and the free edges of the second walls contact the first surface.
10. The structure according to any one of the preceding claims, wherein the cells have a quadrilateral cross-section, preferably a rectangular cross-section, most preferably a square cross-section.
11. A kit of parts of a structure comprising: a first sub-structure comprising: an array of first walls; a first surface, the first walls arranged to project away from the first surface, the first walls comprising an arrangement of slots for locating second walls therein; and a second sub-structure comprising: an array of second walls; a second surface, the second walls arranged to project away from the second surface, the second walls arranged to be locatable in the arrangement of slots of the first walls, thereby to form one or more cells between: two of the first walls; two of the second walls; a region of the first surface; and a region of the second surface.
12. A pallet comprising a structure according to any one of claims 1 to 11.
13. The structure according to any one of claims 1 to 10, kit of parts of a structure according to claim 11, or a pallet according to claim 12, wherein the structure is a board or a pallet component.
14. A method of manufacture of the structure according to any one of claims 1 to 11 comprising: providing a first sub-structure comprising: an array of first walls; a first surface, the first walls arranged to project away from the first surface, the first walls comprising an arrangement of slots for locating second walls therein; providing a second sub-structure comprising: an array of second walls; a second surface, the second walls arranged to project away from the second surface; and locating the second walls in the arrangement of slots of the first walls, thereby to form one or more cells between: two of the first walls; two of the second walls; a region of the first surface; and a region of the second surface.
15. The method according to claim 14, wherein the method comprises forming the first substructure and/or second sub-structure by pleating a sheet material, thereby to form the walls of the sub-structure; and, optionally, in forming the first sub-structure, the method comprising providing slots in the first walls, or, alternatively, providing slots in the sheet material prior to pleating.