WO1996017784A2

WO1996017784A2 - Cardboard pallet

Info

Publication number: WO1996017784A2
Application number: PCT/GB1995/002827
Authority: WO
Inventors: Brian Patrick Johnson
Original assignee: Brian Patrick Johnson
Priority date: 1994-12-06
Filing date: 1995-12-04
Publication date: 1996-06-13
Also published as: WO1996017784A3; AU3989895A; IL116263A0; GB9711371D0; GB2310193A

Abstract

A flat blank (1) of corrugated cardboard material for forming a structural member, such as a pallet tray, has first (2), second (4), third (6) and fourth (8) wall panels hingedly connected along adjacent side edges at lines of weakness (10, 12 and 14). The first wall panel (2) has a further line of weakness (16) formed proximate a free side edge to define an elongate rectangular fixing tab (18). To form a beam or beams having at least four walls, the blank (1) is foldable at a plurality of lines of weakness (34a-g, 38a-g) made therein to provide double thickness walls.

Description

CARDBOARD PALLET

The present invention relates to a structural member for use in packaging.

Conventionally, containers for goods have been stored and transported on structural members such as pallets which have usually been of timber construction. Timber is a disadvantageous material for pallets as it is heavy, splinters and is likely to fracture when dropped, particularly when allowed to fall so that a corner of the pallet impacts the ground first. There have therefore been many attempts to provide a pallet and/or other structural member which overcomes these disadvantages.

Corrugated cardboard construction pallets have been proposed, such as those described in British Patent Specification No. 1 519 741 (ASHTON) wherein a rectangular box is formed of a blank of stiff material and includes four side walls supporting pairs of opposing bottom closure flaps which overlap one another and are provided with tubular bearers which are spaced apart and extend across the bottom of the box, the bearers being formed by a second folded blank of stiff material. This box has the disadvantage that the bearers are not integrated with the box thereby weakening the overall structure. That is, the bearers must be assembled separately and then fitted to the box. Disadvantageously, the weight of the box is supported by the relatively thin bottom wall of the box when it is lifted by the tines of a forklift truck; moreover the bottom of the box and its contents are easily damaged if the tines are advanced at too high a level.

It is an object of the present invention to provide an improved structural member for use in packaging which is strong, resistant to impact, simple to assemble and disassemble, easily stored and biodegradable.

It is a further object of the present invention to provide a member which is particularly suited to self- assembly.

It is a still further object of the present invention to provide an improved blank for a structural member for use in packaging, which is also strong, resistant to impact, simple to assemble and disassemble, easily stored and biodegradable.

According to the present invention there is provided a blank for forming a structural member comprising a portion of stiff material foldable at a plurality of lines of weakness made therein to form a beam or beams having at least four walls, at least one of which walls is of two or more thicknesses.

Preferably, the facing surfaces of least one of the double or more thickness walls are securable to each other. For additional strength, the blank may be foldable at eleven lines of weakness to form four triple thickness walls.

A palletised tray or box may be formed from such a blank which further includes a plurality of lines of weakness to form four wall panels, and a pair of floor panels, the floor panels being supported, when assembled, on said beams. If additional lines of weakness are included in the blank to form four top panels, then a palletised container may be assembled. Alternatively, the blank may be formed with a free end which, when assembled, extends proud of the beam to define a marginal portion such that two such members may be connected by a separate floor panel which is located between the marginal portions. As a variant, the marginal portion could be extended thereby forming a floor panel for connection to a correspondingly extended blank, such that when both blanks are assembled, they may be oriented such that they form a pallet having a double thickness floor portion.

To facilitate the use of a loop of tape to secure a member formed from a blank, one or more of the lines of weakness might incorporates guide means for a loop of tape, perhaps in the form of a pair of parallel slits forming a notch or seat for the tape.

According to a further aspect of the invention, there is provided a method of forming a structural member, comprising applying adhesive to a blank of stiff material having a plurality of lines of weakness formed therein, and folding said blank about said creases to from a rigid structural member.

Preferably, the adhesive is applied to the blank as strips of double sided tape, although the adhesive may be applied directly to the blank or member. To facilitate assembly, the blank or member may be supplied to a user with the adhesive already applied or it may be supplied for the user to apply himself.

It is envisaged that where appropriate, the above structural member and method will be particularly suited to enable the use of poorer grades of cardboard.

As an aid to identification of goods carried by a pallet or tray, or box, a bar-code or the like may be directly printed onto the pallet. In order to aid in understanding the invention some specific embodiments thereof will now be described by way of example and with reference to the accompanying drawings, in which:

Figure 1 is a plan view of a flat blank for a pallet according to the invention;

Figure 2 is a plan view of a flat blank for a pallet of a second embodiment of the invention;

Figure 3 is an end elevation view of the assembled pallet of Figure 2;

Figure 4 is a similar view of a variant of the .second embodiment;

Figure 5 is a plan view of a blank for a structural member of a third embodiment of the invention;

Figure 6 is an end elevation view of a pair of structural members of Figure 5, forming a pallet in conjunction with a floor panel;

Figure 7 is a plan view of a blank of a variant of the third embodiment;

Figure 8 is an end elevation view of the variant of Figure 6 showing an assembled pallet;

Figure 9 is a perspective view of a further variant of Figure 6, showing a set of assembled members secured to a conventional packing case;

Figure 10 is a plan view of a blank for a structural member according to a fourth embodiment of the invention;

Figure 11 is side view of the structural member of Figure 10, shown assembled;

Figure 12 is a plan view of a flat blank for a palletised container of a fifth embodiment of the invention;

Figure 13 is a plan view of a blank for palletised container according to a sixth embodiment of the invention; and

Figure 14 is perspective view of the palletised container of Figure 13, shown assembled. Referring to Figure 1, there is shown a flat blank l of corrugated cardboard material having fold or crease lines shown in ghost. The blank 1 has first 2, second 4, third 6 and fourth 8, wall panels hingedly connected along adjacent side edges at creases 10, 12, and 14. The first wall panel 2 has a further crease 16 formed proximate a free side edge to define an elongate rectangular fixing tab 18. A pair of leg-forming panels 20,22 and a pair of floor panels 24,26 depend from the bottom edge of the second and fourth wall panels 4,8, and the first and third wall panels 2,6, respectively. Each floor panel 24,26 is generally rectangular in shape, whereas each leg-forming panel 20,22 is divided into seven elongate rectangular portions of alternating narrow and wide breadth by fold lines 34(a- g),36(a-g), such that the free end portion 38,40 of the panel 20,22 is of narrow breadth and the fold line 34a,36a is parallel and proximate the bottom edge of the side wall 4,6, but is displaced vertically therefrom. The blank 1 is formed into a pallet tray by folding along the crease lines to form a parallelpipedal box. The wall panel 8 is attached to the wall panel 2 by the tab 18 using adhesive or staples. The double parallel foldlines 32a,32b and 36a,36b allow the floor portions 24,26 to smoothly overlap each other before being bonded or stapled together. The floor portion is supported on the legs 46,48 which are formed firstly by applying adhesive to portions of the leg panel 24,26 to be contacted, and then by folding in the same sense each portion of the leg panel in turn about the fold lines 28(a-g) ,38(a-g) , commencing with the fold 28g,38g nearest the free end 40,42, inwardly through 90° so as to form a double walled rectangular cross-section leg with the free end portion 40,42 enclosed within the leg.

Turning to Figures 2 and 3 which show a second embodiment of the invention. A blank 101 of corrugated cardboard material has fold or crease lines shown in ghost. The blank has a rectangular floor panel 102, and a pair of leg-forming panels 104,106 extending from opposite edges 108,110 of the floor panel 102. Each leg forming panel 104,106 is divided into seven rectangular elongate portions 112(a-g) ,114(a-g) by fold lines including, and extending parallel to a crease at respective edges 108,110 of the floor panel 102. The blank 101 is formed into a pallet 201 in which the floor portion 102 is supported on legs 116,118 which are formed by applying adhesive to portions of the leg panel 104,106 to be contacted, and then folding in the same sense each portion of the leg panel 104,106 in turn about the fold lines, commencing with the fold nearest the panels 104,106 free end 128,130, inwardly through 90° so as to form a double walled rectangular cross-section leg 124,126 with the free end 128,130 enclosed within the leg 124,126.

In a variant of the second embodiment, shown in Figure 4, a composite three legged pallet 301 is formed by placing a pair of such pallets 201 side by side and applying adhesive to their contacting surfaces 302,304 of the adjacent legs. A separate rectangular floor panel 306 is laid over the pallet 201 floors to strengthen the composite pallet 301.

Figure 5, shows a third embodiment of the invention being a structural member for .use in packaging construction. A flat blank 401 of corrugated material is divided into eight rectangular elongate portions 402(a-h) by fold lines (shown in ghost), such that when folded into a box section beams described above in relation to the preceding embodiments, the external free end portion 402h is so dimensioned to form a lip 410 which is upstanding from the surface of the member. Turning to Figure 6, this shows a pair of assembled structural members 501a,501b forming the legs of a pallet 502 whose floor portion 504 is defined by a pair of superimposed rectangular floor panels 506a,506b. Each lip 510a,510b of the members 501a,501b abuts a corresponding edge of the floor panels 506a,506b. In use, a storage container or box (not shown) is guided accurately onto the pallet 502 by the channel defined by the lips 510a,510b and subsequently secured thereto by means of a strap (not shown) or the like.

Figure 7, show a variant of the third embodiment in which the external free end portion 602h of the member 601 is further extended to form an enlarged lip 610 of rectangular shape.

A pair of such members 701a,701b may aligned, as shown in Figure 8, so that their respective portions 702h form upper and lower floor panels 706a,706b. The lower panel 706b is sandwiched between the upper panel 706a and the other member 701b at its free end whilst the upper panel 706a overlays and is bonded or stapled to the lower panel 706b.

Figure 9, shows a fourth embodiment of the invention, being a structural member for use in packaging construction. A flat blank of corrugated material is divided into eight substantially square portions by fold lines, such that when folded into a box section beam described above in relation to the preceding embodiments the member 801, resembles a cube, and may be attached to a box 810 on its underside 812. Each member 801 is secured to the box 810 by a suitable fixing method, e.g. adhesive tape, staples, and thereby provides a support which allows the ingress of tines of a forklift (not shown). Referring to Figures 10 and 11, there is shown a flat blank 910 of corrugated cardboard material, being a structural member 905 for use in packaging construction. The flat blank 910 is divided into eight rectangular elongate portions 912(a-h) by fold lines (shown in ghost), such that when assembled the blank resembles a cube, and may be attached to a box (not shown) on its underside. In order to assemble the structural member 905, double-sided adhesive strips 914,915 are first applied to the surface of the blank as illustrated, to form a bond between facing surfaces of the blank 910 at its free ends. The strip 914,915, which may be supplied separately or already attached to the blank, has a release film (not shown) protecting its surface to be exposed, and which film is removed immediately prior to assembly. The member 905 is assembled by folding in the same sense each portion 912(a- h) of the blank in turn about the fold lines commencing with the fold nearest the free end portion 912h to be enclosed within the member 905, inwardly through 90° so as to form a double walled rectangular cross-section member 905.

A number of such members 905 may be secured to a box or tray or suchlike (not shown) to form a palletised container or pallet tray, by a suitable fixing method, e.g. adhesive tape, or staples. Once attached, the members provide a support which allows the ingress of tines of a forklift (not shown). In a non-illustrated variant of the embodiment, the blank 910 may be provided with additional tabs or wings which, when assembled, provide enhanced strength and/or reinforcement to the connection to the box or tray.

Referring now to Figure 12, there is shown a flat blank 930 of corrugated cardboard material having fold or crease lines shown in ghost. The blank 930 has first 932, second 934, third 936 and fourth 938, wall panels hingedly connected along adjacent side edges at creases 940, 942, and 944. The first wall panel 932 has a further crease 946 formed proximate a free side edge to define an elongate rectangular fixing tab 948. Four top closure panels 950, 952, 954, and 956 extend from creases 958,960,962,964 at respective upper edges of the wall panels 932,934,936,938. A pair of leg-forming panels 966,968, and a pair of floor panels 970,972 depend from the bottom edge of the second and fourth wall panels 934,938, and the first and third wall panels 932,936, respectively. Each floor panel 970,972 is generally rectangular in shape, whereas each leg-forming panel 966,968 is divided into seven elongate rectangular portions by fold lines 974(a-g) ,976(a-g) , such that the fold line 974a,976a is parallel to and displaced vertically from, the bottom edge of the side wall 934,938. The blank 930 is formed into a palletised container by folding along the crease lines to form a parallelpipedal box. The wall panel 938 is attached to the wall panel 932 by the tab 948 using adhesive or staples. The floor panels 970,972 are supported on the legs which are formed by folding, in the same sense, each portion of the leg panel 966,968 in turn about the fold lines 928(a-g) ,938(a-g) , commencing with the fold 928g,938g nearest the free end 978,980, inwardly through 90° so as to form a double walled rectangular cross-section leg with the free end portion 978,980 enclosed within the leg. However, as an initial step in forming the legs, strips of double-sided adhesive tape (not shown) are applied, as required, to the elongate portions of the leg panels 966,968 in order to secure respective facing surfaces of the panel 966,968, and thereby to prevent the resulting folded beams from unravelling.

Referring to Figures 13 and 14, there is shown a palletised container 1001 which is formed from a unitary corrugated cardboard blank 1010 having fold or crease lines shown in ghost. The blank 1010 has first 1012, second 1014, third 1016 and fourth 1018, wall panels hingedly connected along adjacent side edges at creases 1020, 1022, and 1024. The first wall panel 1012 has a further crease 1026 formed proximate a free side edge to define an elongate rectangular fixing tab 1028. Four top closure panels 1030, 1032, 1034, and 1036 extend from creases 1038, 1040, 1042, and 1044 at respective upper edges of the wall panels 1012, 1014, 1016, and 1018. A pair of leg-forming panels 1046,1048, and a pair of outer and inner floor panels 1050,1052 depend from the bottom edge of the second and fourth wall panels 1014,1018, and the first and third wall panels 1012,1016, respectively. Each floor panel 1050,1052 is generally rectangular in shape, whereas each leg-forming panel 1046,1048 is divided into seven elongate rectangular portions by fold lines 1054(a-g) ,1056(a-g) , such that the fold line 1054a,1056a is parallel to and displaced vertically from, the bottom edge of the side wall 1014,1018. The inner floor panel 1052 has a semi-circular notch 1058 formed in the free-edge 1060 opposite the crease connecting the panel 1052 to the wall 1016. In use, the notch 1058 allows the panel to be lifted more easily and thus permit the container to be broken down more rapidly. To provide a location for strapping, such as nylon tape, when the container is assembled, and two pairs of parallel slits 1062a,1062b and 1064a,1064b are made across and perpendicular to the creases 1038,1042 formed between the first and third walls 1012,1016 and their corresponding closure panels 1030,1034, respectively. In addition, a further two pairs of parallel slits 1066a,1066b are made across and perpendicular to the crease 1068 between the first wall 1012 and the outer floor panel 1050.

The blank 1010 is formed into a palletised container by folding along the crease lines to form a parallelpipedal box. The fourth wall panel 1018 is secured to the first wall panel 1012 by the tab 1028 using adhesive or staples. The inner floor panel 1052 is supported on the outer floor panel 1050 which is itself supported by the legs which are formed by folding, in the same sense, each portion of the leg panel 1046,1048 in turn about the fold lines 1054(a- g) ,1056(a-g) , commencing with the fold 1054g,1056g nearest the panel's free end 1070,1072, inwardly through 90° so as to form a hollow double-walled rectangular cross-section leg with the free end portion 1070,1072 enclosed within the leg. Once the legs have been formed in this way, strips of adhesive tape 1074 are applied to the panels around the open ends of the legs, as required, to prevent the legs unravelling.

In use, the container 1001 is filled prior to folding first the second and fourth closure panels 1014,1018, followed by the first and third closure panels 1012,1016 inwardly, and securing the first and third panels 1012,1016 with a strip of adhesive tape 1076. Then, to provide additional security, a length of nylon tape 1078a,1078b or other suitable strapping, is passed longitudinally through each of the hollow legs and located between respective ones of the pre-formed parallel slits 1062-1066a,1062-1066b, to form a pair of loops encircling the container 1001. The cardboard in the region between slits is compressed by the tape 1078a,1078b as it is tightened, thereby ensuring that the tape 1078a,1078b is located in the depression so formed and thus preventing the tape 1078a,1078b from becoming detached from the container 1001. Furthermore, the tape 1078a,1078b, when tightened, causes its corresponding leg portion to be urged into contact with the outer floor panel 1050, the tension in the tape 1078a,1078b ensuring that the legs are positively held in position with respect to the floor panel 1050, and obviating the requirement for further fastening means such as adhesive tape or staples, for example. It should be noted that only one set of parallel slits is formed at the bottom of the first side wall 1012 of the container 1001 along its crease with the outer floor panel 1050, as the container in this region is of double thickness of cardboard, and therefore more easily able to bear the load exerted thereon by the tape 1078a,1078b, without the risk of tearing or other damage to the container 1001 and/or its contents, as would be the case if slits were formed in the crease between the third side wall 1016 and the inner floor panel 1052.

It will be appreciated by one skilled in the art that the parallel slits 1062-1066a,1062-1066b which locate the tape 1078a,1078b could be replaced by other means for guiding the tape 1078, which could be formed in the blank on the fold line, such as a cut-out, for example.

It will also be understood that various alterations and modifications may be made to the above embodiments without departing from the scope of the invention, and that the invention is applicable to other forms of self assembly packaging. For instance, the floor of the palletised container may be reinforced by inserting a separate, probably cardboard, element of suitable thickness between the floor panels during assembly. Such an element could, if necessary, be secured to one or other of the floor panels. In any case, in order to provide additional strength, the element, if fabricated of corrugated board, could be arranged with its flutes at right angles to those of the floor panels to provide further additional strength.

Claims

CLAIMS :

1. A blank for forming a structural member comprising a portion of stiff material foldable at a plurality of lines of weakness made therein to form a beam or beams having at least four walls, at least one of which walls is of two or more thicknesses.

2. A blank as claimed in Claim 1, wherein at least one of the double or more thickness walls has facing surfaces securable one to the other.

3. A blank as claimed in Claims l and 2, wherein the blank has a free end which, when assembled, extends proud of the beam to define a marginal portion.

4. A blank as claimed in Claim 3, wherein the marginal portion is extended thereby forming a floor panel for connection to a correspondingly extended blank, such that when both blanks are assembled, they may be oriented such that they form a pallet having a double thickness floor portion.

5. A blank as claimed in Claims l and 2, wherein said beams are linked by a contiguous floor panel, which, when assembled, produces a pallet.

6. A blank as claimed in Claims 1 and 2, further including a plurality of lines of weakness to form four wall panels, and a pair of floor panels, the floor panels being supported, when assembled, on said beams to produce a palletised tray or box.

7. A blank as claimed in Claim 6, further including a plurality of lines of weakness to form four top panels, which, when assembled, produces a palletised container.

8. A blank as claimed in any preceding Claim, wherein at least one of the lines of weakness incorporates guide means for a loop of tape for securing the structural member when assembled.

9. A blank as claimed in Claim 8, whθerein the guide means is positioned on the line of weakness such that when assembled, it is situated on an external surface of an at least double thickness portion thereof.

10. A blank as claimed in Claims 8 and 9 as appendant to Claim 7, wherein guide means are formed in lines of weakness forming one pair of parallel edges of the assembled palletised container top and in a corresponding parallel edge of the container bottom.

11. A blank as claimed in any preceding Claim, further includβing a bar code or the like printed directly thereon.

12. A blank as claimed in any preceding Claim, wherein each beam is foldable at seven lines of weakness to form four double thickness walls.

13. A blank as claimed in any one of Claims l to 10, wherein each beam is foldable at eleven lines of weakness to form four triple thickness walls.

14. A method of forming a structural member , comprising applying adhesive to a blank of stiff material having a plurality of lines of weakness formed therein, and folding said blank about said creases to from a rigid structural member.

15. A method as claimed in Claim 14, wherein the adhesive is applied to the blank as strips of double-sided adhesive tape. ₁6. A structural member formed from a blank as claimed in Claims 1 to 13.