SE510634C2 - Process for making a pallet, and system for handling it - Google Patents

Abstract

The invention relates to a method of producing a pallet that comprises an upper, load-supporting part (11), a lower part (13) spaced from said upper part (12) with the aid of spacers (15). The invention is characterised by gluing to a first, elongated sheet-like core (13) of predetermined thickness a surface covering of liquid-proof sheet material (12) so as to form a load-supporting upper part (11), and gluing to the mutually opposing side surfaces of a second, elongated sheet-like core (14) of predetermined thickness a liquid-proof covering sheet (12), such as to form a bottom part (14). The bottom part consisting of said core and said liquid-proof covering material is worked to form spacing blocks (15) of predetermined height. The top and bottom pallet-parts (11, 12) can be packed together while using the material obtained from the cutting process and from which spacing blocks are formed, and said spacing blocks are fitted so as to provide a finished pallet (10).

Description

lm k.) ltn F) t, Il J (D 510 634 å WO 93/21076 discloses a pallet comprising a load-bearing surface of a sheet-like material which is folded to also form a frame.

The advantage of the pallets of the stated known type is that they are light and thus have a weight which is clearly less than the weight of a conventional wooden pallet. The downside is. as already mentioned. that they do not tolerate the usually harsh handling. The corrugated cardboard must be surface-treated to resist moisture and the cost picture is therefore less favorable. In addition, these pallets are still rather bulky and therefore the transport cost per pallet becomes relatively high.

The object of the present invention is to provide a method for manufacturing a pallet. built on the principle of prefabricated parts. and which optimally utilizes materials available on the market with a minimum of material waste. A pallet produced according to the process can be manufactured in large quantities by simple means and transported in a non-bulky manner ocfu or stored. The pallet's final assembly into the finished product takes place quickly and with simple mechanical aids.

Such a pallet is achieved by the characterizing part of the method claim 1.

The dependent subclaims indicate advantageous procedural steps.

System cracks 13 and 14 indicate in a defined manner how the new method can be used to package in a practical and cost-saving manner. transport and / or store a pallet manufactured in accordance with the procedure.

In order to better the first invention, two selected embodiments thereof are described below with reference to the accompanying drawings. where lm i) l \) fx) U '510 654 å Fig. 1 in perspective shows a First drying of a pallet according to the thawing seen trân the upper side.

IN! qo to shows in perspective the pallet in tig. l from the bottom. whereby dashed lines indicate future openings to be cut out of the material.

Fig. Za shows the underside of the pallet. wherein the openings are machined to form individual blocks.

Fig. 3 shows a piece of material cut out from the underside of the pallet.

Fig. 4 shows four cut-out material pieces according to fig. 3 which stacked and glued on each other after machining form spacers.

Fig. 5 shows on a large scale a corner portion of the pallet in fig. 1 or 2.

Figs. 6 and 6a show a second drying of the lower part of the pallet according to the invention. bottom part.

I tig. 1 and 2, the pallet according to the thawing is generally denoted by the reference numeral 10. Fig. 1 shows in perspective the flat load-receiving upper part 11 of the pallet 10. which consists of a disc-borne liquid-resistant surface layer 12 which is glued to a disc-toned core material 13. This disc-shaped surface layer 12 can protrude with a dry part from the core material 13, which is indicated in fig. 1 and 2 with dashed lines and has taken the reference numeral 12 'should allow this protruding piece of material via fold lines to be folded up or down. which is a torso part when stacking piles on top of each other according to the thawing. The opposite lower surface of the core material 13 is also provided with the same liquid-resistant surface layer 12 (12 '). thereby forming a sandwich-like composition.

The core material 13 consists with Advantage of a lightweight material. which in the example shown consists of an expanded plastic of polystyrene. Lex. cellplast. For a thank you, however, it is obvious that other materials can also serve as core material. The t J 510 634 few expanded type of plastic has been chosen partly due to the light weight but also its resistance to liquids. as it consists of about 98% air and 2% material.

The two surface layers 12 consist in a preferred embodiment of a so-called liquid carton. i.e. a number of compressed paper layers. which is tested by gluing to the two opposite surfaces of the core material 13. Such a surface layer 12 can advantageously have a thickness of about 1-2 mm. The core material 13 suitably has a thickness of about 20 mm.

The pallet 10 in tig. l underside. thus its base plate or lower part l-l. shown in perspective in fig. 2. This base plate or lower part 14 is made in the same way as the load-bearing upper part ll. i.e. it consists of the core material 13 which on opposite side surfaces is coated with the surface layer 12 (12 ') consisting of a liquid-resistant material. Reference numeral IS denotes a number of spacers which are intended to be attached at intervals and in the usual manner to the underside of the upper part 11 and the upper side of the lower part 11 to form a given distance between the upper part 11 and the lower part 14 but also to between these spacers form openings so that the forks of a forklift can be inserted to lift and lift a freight pallet. These spacers consist of the material cut out of the pallet 10 in the underside of Fig. 2. or bottom part l-l. thus a material with a sandwich-like composition coated on the side surfaces of the core material 13 with a liquid-resistant surface layer.

A bottom part 14 of a pallet 10 according to the invention which is formed with four punched-out hatches or openings of predetermined size and in Fig. 2 denoted by the reference numeral 16 are arranged around a central cross and connected to these hatches form a frame. which means that the supporting surface is two thirds of the surface of the entire pallet ILH, in ml l)) P.) LJ '31010 634 To further strengthen the pallet according to the present invention, the corner and side hinges 17 can be applied in the manner shown in fig. 1 and 2. Such braces may advantageously be made of the same material which forms the surface layers 12.

It is also within the scope of the invention that the material frothed from the bottom plate is processed to form the spacers 15 between the upper and lower part of the pallet 10.

In a process according to the present invention for manufacturing a pallet, a first elongate sheet-shaped core material 13 of a given thickness is coated on its opposite side surfaces with at least one core material 13 covering surface layer of a liquid-resistant. disc-shaped material 12 (12 ') for the purpose of forming a load-bearing upper part 1 1. to a second. elongate sheet-shaped core material 13 of a given thickness on its opposite surfaces is coated with at least one core material 13 covering surface layer of a liquid-resistant sheet-bearing material 12 (12 ') for the purpose of forming a lower part. the bottom part 14. that the lower part 14 is processed so. that a number is formed. preferably four equally large openings 16 and that the sandxvich material obtained by the processing is in turn processed sa. that spacer blocks are formed. This latter processing can take place as follows. that a piece of material cut out by means of, for example, water cutting in the same cut is cut into equal parts. Lex. nine equal parts (Fig. 2a) which are then joined together by gluing so that a spacer block with given dimensions is formed.

For example, four pieces of material can be glued together into a spacer block. A standard pallet normally requires nine spacers spaced apart. Such a spacer block comprises, for example, four core material layers 13 and eight liquid-resistant sheet-like cardboard-like layers 12 and creates a very resistant spacer with very high bearing capacity. By such a method, the raw material contained in the pallet is optimally utilized and negligible material waste occurs. By arranging such a composite spacer 15 on a vertical edge. i.e. that the core material 13 in such a member IU '1a IF, in 510 634 g is oriented perpendicular to the core material 13 in the upper and lower planes 11 resp. 14. an optimum strength against deflection is achieved. A further advantage of such a manufacturing method is that it is preferred to stack an upper part 11 and a lower part 14 included in the pallet on top of each other and then to apply the processed material from the foamed openings in said openings thereby creating a flat package with a thickness of about 25mm which can be easily transported to the consumer who then 'mounts the spacers himself at the given places.

If then the described processing process of the lower load plane openings indicated is performed by water cutting. the piece of material 16 with the divided spacers by frictional force will remain and only a light stroke is required on the surface of the piece of material 16 to loosen the spacers and glue them together in a suitable number and then apply so glued spacers between upper and lower planes 11 and 1, respectively. . 14.

This also brings with it the very great advantage from a freight point of view of two sandwich parts. namely 1 1 and 14 are packed together to form a flat package and can then at a cost which is currently one third of the cost of a finished pallet. shipped to a consumer.

It is realized. that the pallet indicated by this invention can be mass-produced at a cost which is clearly less than that of a conventional wooden pallet. No new machine constructions for the manufacture of the new pallet are needed as the machine park already exists.

To achieve optimal strength, the pieces of material extracted from the sheet material 16 can be removed. which are glued together to form spacers 15. during assembly are so applied. that the incoming core material is oriented perpendicular to the core material in the upper OCh [out I ”Z 510 634 lower part. Furthermore, it is gained that a surface layer 12 will be turned outwards and thereby the spacer blocks become more resistant to impacts and shocks.

Figs. 6 and 6a show a second method for forming the lower part of the pallet according to the invention. bottom part.

Fig. 6 illustrates the lower part or bottom part of a pallet according to the invention thus the part corresponding to the sandwhich bottom part 14 in fig. 1 and 2. In Figure 6, this part has been given the reference numeral 14 '. As can be seen from this drawing figure, the bottom part 14 'has been worked as follows. that a number of identically equal beam-like pieces 144-150 are formed. In it in tig. 6 and 6a, the applicant has started from a pallet with the dimensions 1200 x 800mm. thus a s.k. helpall. With that assumption, the number of beam pieces is 144-150 to seven. Of these seven beams, the beams 144, 145 and 146 are intended to form the load-bearing beams of the pallet which are oriented in the manner shown in FIG. Thus, with a pre-given mutual distance. In practice, this means that the Code l44 resp. 146 form the side beams of the pallet while the beam 145 is centrally arranged between the beams I44 and 146.

The remaining four beams l47.l48.l49.l50. further processed so that each beam is divided into nine identically equal blocks a-i. as a result of which a total of thirty-six blocks are formed from these four beams. In the case of a pallet in this embodiment, it must be completed by a consignee. tea.\. a user. no assembly takes place and it is obvious to a tiackman that a prospective pallet in this embodiment forms a flat rectangular package. which after wrapping can be easily transported with a suitable means of transport and mounted on site. In the case of 510 654 g in the case a lower part of a pallet designed in the manner described must also be handled in this way. that a pallet is formed ready for use. comprises the method of a) applying the beams 144,15 to a substrate. 146 in the manner shown in Fig. 6a b) in that the bottom part 14 'incl. the liquid protective surface layer has a given dimension. come four stacked and glued spacer blocks stacked on top of each other. Lex. blocks abc and d. to form a single spacer block of predetermined height and a stack of blocks thus formed is placed above the beam 144 at the place marked by the number 1. The next group of blocks of four is placed at the place 4 on the beam 144 and finally a third group is applied about four blocks on the beam 144 at place 7. Correspondingly, the other two beams H5 and 146 are provided with correspondingly placed groups of four blocks at the places marked with the numbers 2.5.8 resp. 3.6 and 9. Each group of blocks of four is glued to resp. beam. Then the free end surface is provided with resp. group of blocks with an adhesive and then applied to it (upper. load-bearing surface. Once again it should be pointed out that the way of processing the lower plane of the pallet may be different from that described above. The described and shown utterances thus refer to a standardized so-called full pallets Other types of pallets may occur, eg so-called half pallets, where the total number of spacer blocks is less than thirty-six, whereby, however, the principle for the processing of the bottom part is maintained, but that the processing is adapted to the current pallet size.

The pallet according to the present invention has a number of advantages. of which may be mentioned: a) the constituent elements are easily accessible and light in weight. b) unassembled pallet can be transported long distances at reasonable prices. involving centralized mass-produced manufacturing. lm)) If IP; g 510 634 c) the design of the bottom part provides flexural strength in all directions. d) improved stability when stacking pallets on top of each other. e) the liquid-resistant surface layer at the surface of the pallet can be formed projecting over the core material with the possibility of folding up to form one or more collars. f) even though liquid cotton currently appears to be the best surface layer, other materials with good tensile strength may be considered.

It will be apparent to one skilled in the art that the inventive concept may be modified within the scope of the appended claims. It has been mentioned earlier in this description that the material may be other than an expanded plastic. although such is preferable. In the same way, the surface layers surrounding the two opposite side surfaces of the core material can be a suitable type of plastic. The pallet proposed according to the invention is environmentally friendly.

By heating, the polystyrene can be melted and recycled into new polystyrene and the cardboard material of the surface layers can be reused.

The method according to the invention can then be advantageously used in a packaging system. . transport and / or warehousing by: a) laying the first elongated and surface-loaded load-bearing upper part on a base. b) the second elongate and surface-covered lower part after processing is placed directly on the upper part. c) the formed. flat package. possibly provided with a cover casing, transported to a recipient or stored.

Analogously, according to claim 13, prefabricated pallets according to the invention can be easily stacked on top of each other to form a homogeneous package.

Claims (9)

The pallet according to the invention is based on the principle that a single type of sandwich material shall be used for all components included in the pallet, thus upper support plane, lower stabilization plane and spacer blocks of a given height therebetween. In the present case, The core of this material itself is very light and consists of cell spheres of different sizes which are compressed to a certain density and impervious to liquid by the compression molding closing the cells.By providing opposite surfaces of this core material with disc-shaped surface layers according to this application, a pallet composed according to the invention can be loaded with 2,500 kg + 10% deformation pressure, this seen in the light of the fact that such a pallet has a dead weight of about 5,000 g. competing pallets, including the fact that the components included in the pallet are available ngliga merchandise. Waste generated during the manufacture of the proposed pallets is negligible. Patent claims 1. A method of manufacturing a pallet comprising a load receiving. preferably an unbroken upper part and a lower part oriented at a distance from the upper part. wherein a number of spacers are arranged at a distance from each other between the upper and the lower part and loaded at them. characterized in that a first elongate sheet-shaped core material (13) predetermined thickness on opposite surfaces by gluing is coated with at least one. the core material covering surface layer of a liquid-resistant sheet material (12) in order to form a load-bearing upper part (11). a second elongate sheet material (13) having a predetermined thickness. Iw tgn Im t) f \ .J kr! 510 634 ll the core material. opposing side surfaces by lining are coated with a liquid-resistant sheet material in order to form a lower part (14). the bottom part, and of that the lower. of core material and liquid-resistant disc-shaped material consisting of the bottom part (14) are processed so that spacer blocks (15) with a dry-determined height are formed. that the upper and the lower part (11 and 14, respectively) can be packed together with the material recovered by the cutting process and that assembly of said spacer blocks (15) takes place to form a pallet. Method according to claim 1, characterized in that the lower. of core material and liquid-resistant disc-dry material consisting of the bottom part (14) is processed so that a number of closed openings (16) are formed. that the material obtained by said processing is further processed in this way. that spacer blocks (15) are formed. Method according to claim 1, characterized in that the lower. of core material and liquid-resistant sheet material consisting of the bottom part (14) is processed so that it is formed. a number of identical beams (144-150). that preferably three of these beams are oriented. to serve as load-bearing beams (144-1461) with a mutual distance. that saintliga other beams (147-150) are processed so. that a number of spacer blocks are formed. with pre-given dimensions. that the same number of blocks are loaded next to each other to form a stack of spacer blocks (a-i). wherein one end of the stack is attached at preferably three places on a supporting beam and that the opposite end surface of the stack is loaded at the rear side of the upper one. the load-bearing part. A method according to any one of claims 1-3. characterized in that a spacer (15: a-i) is formed by joining together two or more pieces of material obtained from the foamed material (16) in the lower part (14). (i U) 510 634 12 Method according to one of the preceding claims. characterized in that the core material consists of extruded expanded polystyrene plastic. for example cellular plastic. Procedure according to one or more of the preceding claims. characterized in that the load-bearing plane (17) and the bottom plane (14: 14 ') are placed on top of each other. that the pieces of material (16) which are intended to form spacer blocks (15). placed in the opening or openings in the base plate thereby forming a homogeneous package. Method according to claim 1, 2 or 3, characterized in that the first and the second core material (12.13) have identical materials with identical dimensions. 8. Packaging system. transport and warehousing of a pallet manufactured in accordance with any one of claims 2.3. characterized in that a) the first elongate and surface-loaded load-bearing upper part (12) is laid on a base. (b) the second elongate and surface-layered lower part (13) is placed directly on the upper part after machining. c) the formed. flat package. possibly provided with a cover. transported to a recipient or stored. System according to claim 13, characterized therefrom. that a) the desired number of load-bearing and surface-covered upper parts (12) are stacked directly on top of each other. b) that a corresponding number of lower parts (13) provided with surface layers are placed above the upper parts (12) after machining and design of spacers (15). c) that the hal ruins (14) formed by the superimposed lower parts 5115 with the material from which spacer blocks are created. _1_3_ 510 654 d) that the finished rectangular package. optionally provided with an enclosing cover. transported to a recipient or stored.