Pallet stabilizer

A pallet stabilizer formed from a paperboard blank including a central panel having opposing first and second outer longitudinal sides, and opposing first and second lateral sides. At least one beam body is defined by a body flap formed integral with the central panel and comprises a plurality of flap panels connected in series at respective panel fold lines. Two of the flap panels define longitudinally extending opposing beam sides extending transverse to a plane defined by the central panel. One of the flap panels is located distal from the central panel and is hingedly connected to each of the two flap panels defining the beam sides. A glue tab is connected to one of the beam sides and is attached in overlapping relation on the central panel, and opposing longitudinal beam edges are spaced longitudinally inward from the opposing outer longitudinal sides of the central panel.

FIELD OF THE INVENTION

The present disclosure relates to a pallet stabilizer structure and, more particularly, to a pallet stabilizer structure that can be formed from a paperboard blank.

BACKGROUND OF THE INVENTION

Palleted goods, or pallets, are frequently shipped via truckload shipping, e.g., with the pallets loaded in trailers, where numerous pallets can be placed in front-to-back and side-to-side relationship to one another. Due to weight restrictions, setting maximum weights for the freight on a trailer, the pallets may be distributed throughout the trailer to provide a distributed weight along the length and between the sides of the trailer. The distribution of pallets often results in a spacing between adjacent pallets and between pallets and the sides of the trailer. For example, the pallets may be arranged in rows extending in the width direction of a trailer, where the rows can be alternately positioned to the left and right in a zig-zag pattern extending from front to back in the trailer, and alternately leaving spaces between each pallet row and a side of the trailer. Additionally, the alternating rows can include rows that position pallets adjacent to both sides of the trailer, leaving a central space between the pallets on either side. During transportation, the spaces around the pallets can permit the pallets to shift or lean with resulting distortion of, for example, stacked containers forming the pallet. Hence, there is a need for a stabilizing structure that can fill the spaces between pallets and/or between pallets and the sides of a trailer to prevent shifting of the pallets during transport.

SUMMARY OF THE INVENTION

In accordance with an aspect of the invention, a paperboard blank is provided for use in forming a pallet stabilizer. The blank comprises a central panel having opposing first and second outer longitudinal sides, and opposing first and second lateral sides. At least one body flap is hingedly joined to the central panel along a lateral flap fold line generally transverse to the first and second outer longitudinal sides. The at least one body flap has first and second inner longitudinal edges spaced inward from the first and second outer longitudinal sides and extending laterally outward from the central panel. An outer edge is located at a laterally opposing end of the at least one body flap from the flap fold line, and first, second, and third flap panels are connected in series at first and second panel fold lines, respectively. A glue tab is connected to the third flap panel at a third panel fold line, and the flap panels and glue tab are foldable relative to the each other and relative to the central panel to position the glue tab in parallel overlapping relation on the central panel when the paperboard blank is formed into a pallet stabilizer.

A lateral dimension of the glue tab may be less than a lateral dimension of each of the first, second, and third flap panels.

The flap fold line may be located laterally inward on the central panel between the first and second lateral sides of the central panel.

One or more longitudinal score lines may be provided extending laterally across the at least one body flap from the flap fold line to the outer edge and defining a fold or tear location configured for decreasing a longitudinal dimension of the flap.

A support flap may be formed in the at least one body flap and may be supported for pivot movement to engage at least two of the flap panels when the paperboard blank is formed into a pallet stabilizer.

The support flap may be defined by side separation lines substantially aligned with the first and second panel fold lines, and an end separation line extending across the second flap panel.

The at least one body flap may comprise a first body flap, and the blank may further include a second body flap hingedly joined to the central panel along a lateral second flap fold line generally transverse to the first and second outer longitudinal sides. The second body flap may include first and second inner longitudinal edges spaced inward from the first and second outer longitudinal sides and extending laterally outward from the central panel opposite from the first body flap, and an outer edge at a laterally opposing end of the second body flap from the second flap fold line, and first, second, and third flap panels connected in series at first and second panel fold lines, respectively, and a glue tab connected to the third flap panel at a third panel fold line.

In accordance with another aspect of the invention, a pallet stabilizer formed from a paperboard blank is provided. The paperboard blank comprises a generally planar central panel having opposing first and second outer longitudinal sides, and opposing first and second lateral sides. A hollow beam structure including at least one beam body defined by a body flap is formed integral with the central panel and comprises a plurality of flap panels connected in series at respective panel fold lines. Two of the flap panels define longitudinally extending opposing beam sides extending transverse to a plane defined by the central panel. One of the flap panels is located distal from the central panel and hingedly connected to each of the two flap panels defining the beam sides at respective panel fold lines. A glue tab is connected to one of the beam sides and is attached in overlapping relation on the central panel, and opposing longitudinal beam edges are spaced longitudinally inward from the opposing outer longitudinal sides of the central panel.

The opposing beam sides may be each spaced laterally inward from a respective one of the first and second lateral sides of the central panel.

The plurality of flap panels forming the at least one beam body may comprise first, second, and third flap panels connected in series at first and second panel fold lines, respectively, and the first flap panel may be hingedly joined to the central panel along a lateral flap fold line generally transverse to the first and second outer longitudinal sides, and the glue tab may define an outer edge of the body flap.

One or more longitudinal score lines may extend laterally across the flap panels and define a fold or tear location configured for decreasing a longitudinal dimension of the at least one beam body.

A support flap may be formed in the at least one body flap and extend into the at least one beam body to engage at least two of the flap panels.

The support flap may be defined in the blank by side separation lines substantially aligned with the first and second panel fold lines, and an end separation line extending across the second flap panel.

The body flap may comprise a first body flap forming a first beam body, the hollow beam structure may further include a second body flap formed integral with the central panel and forming a second beam body laterally spaced from the first beam body. The second body flap may comprise a plurality of second beam flap panels connected in series at respective panel fold lines, two of the plurality of second beam flap panels defining longitudinally extending opposing second beam sides extending transverse to a plane defined by the central panel. One of the second beam flap panels may be located distal from the central panel and may be hingedly connected to each of the two second beam flap panels defining the second beam sides at respective panel fold lines. A glue tab may be connected to one of the beam sides and may be attached in overlapping relation on the central panel.

In accordance with a further aspect of the invention, a method of forming a pallet stabilizer from a blank is provided. The blank comprises a central panel having opposing first and second outer longitudinal sides, and opposing first and second lateral sides. At least one body flap is hingedly joined to the central panel along a lateral flap fold line generally transverse to the first and second outer longitudinal sides. The at least one body flap has first and second inner longitudinal edges spaced inward from the first and second outer longitudinal sides and extending laterally outward from the central panel. An outer edge is located at a laterally opposing end of the at least one body flap from the flap fold line, and first, second, and third flap panels are connected in series at first and second panel fold lines, respectively. A glue tab is connected to the third flap panel at a third panel fold line. A portion of the flap panels are folded about one of the panel fold lines and the glue tab is adhered in overlapping relation on the central panel. The method includes forming a hollow beam structure and comprises pivoting the first and third flap panels to positions transverse to the central panel to define a beam body, and positioning a support structure within the beam body to substantially resist pivotal movement of the first and third flap panels from the positions transverse to the central panel.

The support structure may comprise a support flap connected for pivotal movement relative to the beam body, and positioning the support structure may comprise engaging the support flap with opposing sides of the beam body.

The support flap may be pivotally connected to the second panel flap and positioning the support structure may comprise frictionally engaging the support structure with the first and third flap panels.

The method may further comprise folding or tearing the at least one body flap at a longitudinal score line extending laterally across the at least one body flap to decrease a longitudinal dimension of the beam body.

DETAILED DESCRIPTION OF THE INVENTION

The present description is directed to a pallet stabilizer that can be provided as a stabilizing structure between pallet stacks, configured as stacks of goods on pallets and generally referred to herein as “pallets,” and can additionally be provided as a stabilizing structure between a pallet, i.e., a pallet stack, and a shipping container wall, e.g., a trailer wall, or similar stable structure. Further, while the goods depicted herein for shipment on the pallet comprise boxes or cartons, it may be understood that the present description is not limited to a pallet of any particular type of goods. As may be understood from the following description, the pallet stabilizer described herein can be used to stabilize one or more pallets, wherein the pallet stabilizer could be provided to a user or customer as a planar unitary blank and quickly configured into an erected configuration for use in stabilizing the pallet(s).

Referring toFIG. 1, a die cut blank10is shown for illustrating one or more aspects of the pallet stabilizer described herein. In a use of the blank10to form a pallet stabilizer8, seeFIGS. 3 and 7, the blank10may be formed of a corrugated cardboard material such as, e.g., single-wall corrugated material, and may be die cut to the shape shown herein, although other materials and variations of the illustrated shape may be provided within the scope of the pallet stabilizer described and claimed herein. The blank10illustrated inFIG. 1is a planar piece of material in which an inner or lower side12is shown facing out of the page and an outer or upper side14, seeFIG. 7, is facing an opposite direction from the inner side12.

As seen inFIG. 1, the blank10extends in a longitudinal direction L1between first and second longitudinal edges, generally designated16and18, respectively, and further extends in a lateral direction L2between first and second lateral edges, generally designated20and22, respectively. The blank10comprises a generally planar central panel24including a first outer longitudinal side16acoinciding with the first longitudinal edge16of the blank10, an opposing second outer longitudinal side18acoinciding with the second longitudinal edge18of the blank10, and opposing first and second lateral sides20a,22a. It may be noted that the elongated direction C of the flutes for the corrugated material of the blank10are oriented to extend parallel to the longitudinal direction L1.

The blank10further comprises a first and second body flaps26,28. The first body flap26is hingedly joined to the central panel24along a lateral flap fold line30extending generally transverse to the first and second outer longitudinal sides16a,18a. The first body flap26includes first and second inner longitudinal edges32,34spaced inward from the respective first and second outer longitudinal sides16a,18a, wherein the first and second inner longitudinal edges32,34extend laterally outward from the central panel24between the first flap fold line30and an outer edge of the first body flap26defined at the first lateral edge20. Further, the first and second inner longitudinal edges32,34extend laterally outward from a pair of first lateral side portions20a1,20a2defining the first lateral side20aof the central panel24on opposing longitudinal sides of the first body flap26.

The second body flap28is hingedly joined to the central panel24along a lateral flap fold line40extending generally transverse to the first and second outer longitudinal sides16a,18a. The second body flap28includes first and second inner longitudinal edges42,44spaced inward from the respective first and second outer longitudinal sides16a,18a, wherein the first and second inner longitudinal edges42,44extend laterally outward from the central panel24between the second flap fold line40and an outer edge of the second body flap28defined at the second lateral edge22. Further, the first and second inner longitudinal edges42,44extend laterally outward from a pair of second lateral side portions22a1,22a2located on opposing longitudinal sides of the second body flap28and defining the second lateral side22aof the central panel24.

The first and second body flaps26,28are configured as foldable members to form respective first and second hollow beam bodies46,48defining a hollow beam structure50, seeFIG. 3. Referring toFIG. 1, the first body flap26comprises a first flap panel52a, a second flap panel52b, a third flap panel52c, and a fourth flap panel52dconnected in series at a first panel fold line54a, a second panel fold line54b, and a third panel fold line54c, respectively. The first, second, and third panel fold lines54a,54b,54cmay comprise crease rule fold lines.

The first flap fold line30is defined at a connection between the first flap panel52aand the central panel24, wherein the first flap fold line30is located laterally spaced inward from the first lateral side portions20a1,20a2. At least a portion of the flap fold line30can comprise a crease rule fold line. A pair of separation lines60a,60bextend laterally along the inner longitudinal edges32,34from the first flap fold line30to the first lateral side portions20a1,20a2, separating the first body flap26from the central panel24and permitting pivotal movement of the first body flap26within the central panel24.

The second body flap28comprises a first flap panel56a, a second flap panel56b, a third flap panel56c, and a fourth flap panel56dconnected in series at a first panel fold line58a, a second panel fold line58b, and a third panel fold line58c, respectively. The first, second, and third panel fold lines58a,58b,58cmay comprise crease rule fold lines. The second flap fold line40is defined at a connection between the first flap panel56aand the central panel24, wherein the second flap fold line40is located laterally spaced inward from the second lateral side portions22a1,22a2. At least a portion of the flap fold line40can comprise a crease rule fold line. A pair of separation lines62a,62bextend laterally along the inner longitudinal edges42,44from the second flap fold line40to the second lateral side portions22a1,22a2, separating the second body flap28from the central panel24and permitting pivotal movement of the second body flap28within the central panel24.

The term “separation line” as used herein may be defined, for example, by a perforated line, or a cut line that extends completely through the material, and may comprise a partial cut through at least one layer of the corrugated material or a cut line interrupted by short sections of bridging (uncut) material.

Referring toFIG. 2, the blank10can be positioned into an erected configuration forming the first beam body46by pivoting the first flap panel52aof the first body flap26upward about the first flap fold line30to position the first body flap26inwardly toward the lateral center of the central panel24, as depicted by arrow A1. The second, third, and fourth flap panels52b,52c,52dare pivoted about the respective panel fold lines54a,54b,54cto position the fourth flap panel52din parallel overlapping relation on the central panel24with the upper side14thereof facing the central panel24, wherein the outer edge defined by the first lateral edge20can be located adjacent to the first flap panel52aat the lateral flap fold line30, seeFIG. 3. It should be noted that the fourth flap panel52dis joined or affixed to the central panel24, as is described in greater detail below

In the erected configuration, the first and third flap panels52a,52cdefine longitudinally extending opposing beam sides of the first beam body46that can extend outward from the central panel24transverse to a plane defined by the central panel24. The second flap panel52bdefines a connecting structure between edges of the beam sides, i.e., at the first and second panel fold lines54a,54b, distal from the central panel24. In particular, in the illustrated erected configuration, the first and third flap panels52a,52ccan extend generally perpendicular to the central panel24, and the second flap panel52bcan extend generally perpendicular to the first and third flap panels52a,52cin spaced relation to the central panel24.

Similar to the above description for erecting the first beam body46, the blank10can be positioned into an erected configuration forming the second beam body48by pivoting the first flap panel56aof the second body flap28upward about the second flap fold line40to position the second body flap28inwardly toward the lateral center of the central panel24, as depicted by arrow A2inFIG. 2. The second, third, and fourth flap panels56b,56c,56dare pivoted about the respective panel fold lines58a,58b,58cto position the fourth flap panel56din parallel overlapping relation on the central panel24with the upper side14thereof facing the central panel24, wherein the outer edge defined by the second lateral edge22can be located adjacent to the first flap panel56aat the lateral flap fold line40, seeFIG. 3. It should be noted that the fourth flap panel56dis joined or affixed to the central panel24, as is described in greater detail below

In the erected configuration, the first and third flap panels56a,56cdefine longitudinally extending opposing beam sides of the second beam body48that can extend outward from the central panel24transverse to the plane defined by the central panel24. The second flap panel56bdefines a connecting structure between edges of the beam sides, i.e., at the first and second panel fold lines58a,58b, distal from the central panel24. In particular, in the illustrated erected configuration, the first and third flap panels56a,56ccan extend generally perpendicular to the central panel24, and the second flap panel56bcan extend generally perpendicular to the first and third flap panels56a,56cin spaced relation to the central panel24.

Further, the first beam side of the first beam body46, defined by the first flap panel52a, can be spaced laterally inward from the first lateral side20adefined by the first and second lateral side portions20a1,20a2, such that a first pair of lateral extensions64a,64bare defined on the central panel24, seeFIGS. 1 and 3. Similarly, the first beam side of the second beam body48, defined by the first flap panel56a, can be spaced laterally inward from the second lateral side22adefined by the first and second lateral side portions22a1,22a2, such that a second pair of lateral extensions66a,66bare defined on the central panel24.

The lateral extensions64a,66acomprise laterally opposing ends of a first support member68athat extends longitudinally outward from first longitudinal ends of the first and second beam bodies46,48, corresponding to the respective inner longitudinal edges32,42of the body flaps26,28. The lateral extensions64b,66bcomprise laterally opposing ends of a second support member68bthat extends longitudinally outward from second longitudinal ends of the first and second beam bodies46,48, corresponding to the respective inner longitudinal edges34,44of the body flaps26,28. Hence, the first and second longitudinal edges32,42and34,44, defining the ends of the beam bodies46,48, are located longitudinally inward from the respective first and second longitudinal sides16a,18aof the central panel24.

Referring toFIG. 1, the blank10can include at least one pair of longitudinally spaced first locking structures70a,70blocated at the inner longitudinal edges32,34of the first body flap26. Similarly, the blank10includes at least one pair of longitudinally spaced first locking structures72a,72blocated at the inner longitudinal edges42,44of the second body flap28. Additionally, in the illustrated embodiment, the first body flap26can include a plurality of pairs of the spaced first locking structures70a,70b, and the second body flap28can include a plurality of the pairs of spaced first locking structures72a,72b.

The first locking structures70a,70b,72a,72bare substantially identical and are defined by cut-out portions of the blank10including a pair of rectangular notches74located on either side of a body tab structure76. The body tab structure76includes a tab outer end76athat can be generally longitudinally aligned with a respective inner longitudinal edge32,34,42,44, seeFIG. 5.

Referring toFIG. 1, the blank10can include two pairs of second locking structures corresponding to the first locking structures70a,70b,72a,72bdescribed above. In particular, the central panel24can comprise at least one pair of longitudinally spaced second locking structures78a,78blocated adjacent or near to the first flap fold line30, and a second pair of longitudinally space second locking structures80a,80blocated adjacent or near to the second flap fold line40. Additionally, in the illustrated embodiment, a plurality of pairs of the first and second pairs of spaced second locking structures78a,78band80a,80bcan be provided longitudinally aligned with corresponding pairs of the respective first locking structures70a,70band72a,72b.

Referring toFIG. 4, the second locking structures78a,78b,80a,80bare substantially identical and comprise a tongue82defined by a separation line84having a longitudinal front portion84aand a pair of outer lateral portions84bextending rearwardly from the front portion84a. A U-shaped separation line86defines a lock tab structure98and includes a longitudinal rear portion86aand a pair of inner lateral portions86bextending forwardly from the rear portion86a. Hinge separation lines88extend parallel to the inner lateral portions86b, and connector separation lines90extend laterally between the hinge separation line88and the outer lateral portions84b. A pair of hinge portions92are defined between pairs of the inner lateral portions86band the hinge separation lines88, wherein the hinge portions92are hingedly connected to the central panel24at a first hinge score line94and are hingedly connected to the tongue82at a second hinge score line96.

When the first and second beam bodies46,48are erected, positioning the fourth flap panels52d,56din overlapping engagement on the central panel24, the first locking structures70a,70b,72a,72bare located adjacent to rear portions of respective second locking structures78a,78b,80a,80b. The tongue82can be pivoted upward and over an adjacent portion of a respective fourth flap panel52d,56d, wherein the hinge portions92can extend generally perpendicular to the central panel24through the rectangular notches74to retain the fourth flap panels52d,56dagainst movement in the lateral direction. Further, pivoting of the tongue82into overlapping relation over the fourth flap panel52d,56dpositions the lock tab structure98over the body tab structure76with the longitudinal rear portion86aof the lock tab structure98generally aligned with the tab outer end76aat a location longitudinally distal from the hinge portions92. Hence, upward movement of the tongue82, away from its locking position against the fourth flap panel52d,56d, can be resisted by engagement of the lock tab structure98against the body tab structure76.

The erected pallet stabilizer8can be placed between two pallets P positioned, for example, in a trailer for shipping, seeFIG. 7, thereby filling a space between the pallets P and limiting or preventing shifting of either one of the pallets P toward the other pallet P. In a use position, the pallet stabilizer8is oriented with the central panel24above the beam bodies46,48, and with the beam bodies46,48extending longitudinally between the two pallets P. The support members68a,68bcan rest on upper surfaces S of the pallets P to vertically support the pallet stabilizer8with ends of the beam bodies46,48positioned closely adjacent to a side of a respective pallet P. It may be noted that, since the elongated direction C of the flutes for the corrugated material extends in the longitudinal direction, the corrugated material is oriented to resist crushing in the longitudinal direction of the beam bodies46,48.

The orientation of the elongated direction C of the flutes further can facilitate resistance to bending of the central panel24in the location where the support members68a,68bextend longitudinally from the beam bodies46,48. However, it should also be understood that the present construction does not necessarily preclude a user from reconfiguring the pallet stabilizer8, such as by intentionally bending one of the support members68a,68bupward, i.e., perpendicular to the plane of the central panel24. For example, in a use of the pallet stabilizer8between a pallet and a trailer wall, one of the support members68a,68bcould be bent perpendicular to the trailer wall (not shown) to permit one end of the beam bodies46,48to be positioned against trailer wall, while the other of the support members68a,68bcan remain parallel to the plane of the central panel24for supporting an opposing end of the pallet stabilizer8on an upper surface of a pallet.

In order to accommodate different loading configurations for placing the pallets in a trailer, and to accommodate different trailer widths, it may be necessary to provide different beam lengths to the beam bodies46,48of the pallet stabilizer8. Hence, in accordance with an aspect of the present blank10, the blank10can be configured to provide one or more predetermined lengths for the beam bodies46,48, to thereby position the longitudinal ends of the beam bodies46,48closely adjacent to the sides of respective pallets P, or adjacent to a side of a trailer. The predetermined lengths for the beam bodies46,48can be selected, for example, with reference to known, i.e., preestablished/conventional, trailer widths that, in combination with the pallets, can create predetermined spaces that can be filled with the pallet stabilizer8.

Referring toFIGS. 1 and 6, the first body flap26can include one or more length score lines32a,32band34a,34bextending parallel to the respective longitudinal edges32,34and defining respective length sections32a′,32b′ and34a′,34b′. The one or more length score lines32a,32band34a,34bcan be longitudinally aligned with respective first locking structures70a,70b. The edges of the first body flap26can folded, or alternatively torn off, at the length score lines32a,32band34a,34bto shorten the beam length defined by the first body flap26. For example, as illustrated inFIG. 6, either or both of the length sections32a′ and34a′ can be folded about the respective length score lines32a,34ato overlap the adjacent length sections32b′ and34b′ prior to folding the first body flap26to form the first beam body46. It may be understood that folding the length sections32a′ and34a′ can expose respective first locking structures70a,70bfor engagement with longitudinally aligned ones of the second locking structures78a,78bon the central panel24. Similarly, a shorter length for the first beam body46can be provided by folding the first body flap edge sections defined by the pair of length sections32a′,32b′ and the pair of length sections34a′,34b′ about the respective length score lines32band34b, positioning the pairs of length sections32a′,32b′ and34a′,34b′ inwardly in overlapping relationship on the first body flap26prior to folding the first body flap26to form the first beam body46. It should be noted that the portions32c,34cof the lateral flap fold line30adjacent to the ends of the length sections32a′,32b′,34a′,34b′ can be formed with perforations or through cuts sufficient to facilitate separation of the length sections32a′,32b′,34a′,34b′ from the central panel24, whereas the remainder of the flap fold line30may be formed as a crease rule fold line, i.e., a non-separating fold line.

The second body flap28may be formed with a construction for forming predetermined shortened lengths for the second beam body48similar to the construction described above for the first body flap26. In particular, the second body flap28can include one or more length score lines42a,42band44a,44bextending parallel to the respective longitudinal edges42,44and defining respective length sections42a′,42b′ and44a′,44b′. The edges of the second body flap28can folded, or alternatively torn off, at the length score lines42a,42band44a,44bto shorten the beam length defined by the second body flap28, in the same manner as described above for forming an alternative length of the first beam body46. Further, the portions42c,44cof the lateral flap fold line40adjacent to the ends of the length sections42a′,42b′,44a′,44b′ can be formed with perforations or through cuts sufficient to facilitate separation of the length sections42a′,42b′,44a′,44b′ from the central panel24, whereas the remainder of the flap fold line40may be formed as a crease rule fold line, i.e., a non-separating fold line.

It may be noted that the length score lines32a,32b,34a,34band42a,42b,44a,44b, of the first and second body flaps26,28can be formed as perforated lines extending fully or partially through the blank10for facilitating either folding or tearing, i.e. separating, the respective length sections32a′,32b′,34a′,34b′ and42a′,42b′,44a′,44b′.

Referring toFIGS. 8 and 9, an optional configuration for a pallet stabilizer108and associated blank110is illustrated. Generally, the optional pallet stabilizer108is half of the pallet stabilizer8described above, wherein elements of the present pallet stabilizer108and blank110corresponding to the pallet stabilizer8and blank10described above are labeled with the same reference numerals increased by 100.

The blank110for forming the pallet stabilizer108comprises a planar piece of material including first and second longitudinal edges, generally designated116and118, respectively, and including first and second lateral edges, generally designated120and122, respectively. The blank110further comprises a generally planar central panel124including a first outer longitudinal side116acoinciding with the first longitudinal edge116of the blank110, an opposing second outer longitudinal side118acoinciding with the second longitudinal edge118of the blank110, and opposing first and second lateral sides120a,122a. The second lateral side122acoincides with the second lateral edge122and generally extends as continuous edge or side from the first outer longitudinal side116ato the second outer longitudinal side118a.

The blank110further comprises a body flap126. The body flap126is hingedly joined to the central panel124along a lateral flap fold line130extending generally transverse to the first and second outer longitudinal sides116a,118a. The body flap126includes first and second inner longitudinal edges132,134spaced inward from the respective first and second outer longitudinal sides116a,118a, wherein the first and second inner longitudinal edges132,134extend laterally outward from the central panel124between the first flap fold line130and an outer edge of the first body flap126defined at the first lateral edge120. Further, the first and second inner longitudinal edges132,134extend laterally outward from a pair of lateral side portions120a1,120a2defining the first lateral side120aof the central panel124on opposing longitudinal sides of the body flap126.

The body flap126comprises a first flap panel152a, a second flap panel152b, a third flap panel152c, and a fourth flap panel152dconnected in series at a first panel fold line154a, a second panel fold line154b, and a third panel fold line154c, respectively. The first, second, and third panel fold lines154a,154b,154cmay comprise crease rule fold lines.

The flap fold line130is defined at a connection between the flap panel152aand the central panel124, wherein the flap fold line130is located laterally spaced inward from the lateral side portions120a1,120a2. At least a portion of the flap fold line130can comprise a crease rule fold line. A pair of separation lines160a,160bextend laterally along the inner longitudinal edges132,134from the first flap fold line130to the lateral side portions120a1,120a2, separating the body flap126from the central panel124and permitting pivotal movement of the body flap126within the central panel124.

The body flap126includes a pair of longitudinally spaced first locking structures170a,170b, and the central panel124includes a pair of longitudinally spaced second locking structures178a,178blocated for engagement with respective ones of the first locking structures170a,170b. Further, plural pairs of first locking structures170a,170band corresponding second locking structures178a,178bcan be provided as described above to accommodate different longitudinal dimensions of the body flap126to form different lengths of a beam body146for the erected pallet stabilizer108.

A first support member168ais defined extending longitudinally outward from a first longitudinal end of the beam body146, corresponding to the inner longitudinal edge132of the body flap126. A second support member168bis defined extending longitudinally outward from a second longitudinal end of the beam body146, corresponding to the inner longitudinal edge134of the body flap126.

The body flap126can include one or more length score lines132a,132band134a,134bextending parallel to the respective longitudinal edges132,134and defining respective length sections132a′,132b′ and134a′,134b′. The edges of the body flap126can folded, or alternatively torn off, at the length score lines132a,132band134a,134bto shorten the beam length defined by the body flap126. The longitudinal dimension of the body flap126can be selectively reduced by folding or tearing off the length sections132a′,132b′ and134a′,134b′ as described above for the blank10. The portions132c,134cof the lateral flap fold line130adjacent to the ends of the length sections132a′,132b′,134a′,134b′ can be formed with perforations or through cuts sufficient to facilitate separation of the length sections132a′,132b′,134a′,134b′ from the central panel124, whereas the remainder of the flap fold line130may be formed as a crease rule fold line, i.e., a non-separating fold line.

The body flap126can be folded as described above for the body flap26of the blank10to the form the beam body146of a hollow beam structure150, seeFIG. 9. Further, the first and second locking structures170a,170band178a,178bcan cooperate with each other as described for the first and second locking structures70a,70band78a,78bto retain the fourth flap panel152din place on the central panel124following folding of the body flap126to form the beam body146. It may be noted that the erected pallet stabilizer108includes lateral extensions164a,164bto one side of the beam body146and includes a laterally extending portion of the central panel124spaced outward from the other side of the beam body146, as defined along the continuous lateral side122aof the central panel124.

Referring toFIGS. 10-13, a further optional configuration for a pallet stabilizer208and associated blank210is illustrated, wherein elements of the present pallet stabilizer208and blank210corresponding to the pallet stabilizer8and blank10, described above with reference toFIGS. 1-7, are labeled with the same reference numerals increased by 200.

Referring toFIG. 10, the blank210for forming the pallet stabilizer208comprises a planar piece of material including first and second longitudinal edges, generally designated216and218, respectively, and further extends in a lateral direction L2between first and second lateral edges, generally designated220and222, respectively. The blank210further comprises a generally planar central panel224including a first outer longitudinal side216acoinciding with the first longitudinal edge216of the blank210, an opposing second outer longitudinal side218acoinciding with the second longitudinal edge218of the blank210, and opposing first and second lateral sides220a,222a. It may be noted that the elongated direction C of the flutes for the corrugated material of the blank210is oriented to extend parallel to the longitudinal direction L1.

The blank210further comprises first and second body flaps226,228. The first body flap226is hingedly joined to the central panel224along a lateral flap fold line230extending generally transverse to the first and second outer longitudinal sides216a,218a. The first body flap226includes first and second inner longitudinal edges232,234spaced inward from the respective first and second outer longitudinal sides216a,218a, wherein the first and second inner longitudinal edges232,234extend laterally outward from the central panel224between the first flap fold line230and an outer edge of the first body flap226defined at the first lateral edge220. Further, the first and second inner longitudinal edges232,234extend laterally outward from a pair of first lateral side portions220a1,220a2defining the first lateral side220aof the central panel224on opposing longitudinal sides of the first body flap226.

The second body flap228is hingedly joined to the central panel224along a lateral flap fold line240extending generally transverse to the first and second outer longitudinal sides216a,218a. The second body flap228includes first and second inner longitudinal edges242,244spaced inward from the respective first and second outer longitudinal sides216a,218a, wherein the first and second inner longitudinal edges242,244extend laterally outward from the central panel224between the second flap fold line240and an outer edge of the second body flap228defined at the second lateral edge222. Further, the first and second inner longitudinal edges242,244extend laterally outward from a pair of second lateral side portions222a1,222a2located on opposing longitudinal sides of the second body flap228and defining the second lateral side222aof the central panel224.

The first and second body flaps226,228are configured as foldable members to form respective first and second hollow beam bodies246,248defining a hollow beam structure250, seeFIG. 12. Referring toFIG. 10, the first body flap226comprises a first flap panel252a, a second flap panel252b, a third flap panel252c, and a glue tab252dconnected in series at a first panel fold line254a, a second panel fold line254b, and a third panel fold line254c, respectively. The first, second, and third panel fold lines254a,254b,254cmay comprise crease rule fold lines. The glue tab252dcan be formed with a relatively short lateral dimension, i.e., relative to the lateral dimensions of the flap panels252a,252b,252c, and can form an attachment structure for attaching a laterally outer end of the third flap panel252cto the central panel224when the body flap226is erected to form the beam body246, as discussed further below.

The first flap fold line230is defined at a connection between the first flap panel252aand the central panel224, wherein the first flap fold line230is located laterally spaced inward from the first lateral side portions220a1,220a2. At least a portion of the flap fold line230can comprise a crease rule fold line. A pair of separation lines260a,260bextend laterally along the inner longitudinal edges232,234from the first flap fold line230to the first lateral side portions220a1,220a2, separating the first body flap226from the central panel224and permitting pivotal movement of the first body flap226within the central panel224.

The first body flap226can also include one or more length score lines232a,232band234a,234bextending parallel to the respective longitudinal edges232,234and defining respective length sections232a′,232b′ and234a′,234b′. The edges of the body flap226can be folded, or alternatively torn off, at the length score lines232a,232band234a,234bto shorten the beam length defined by the body flap226. The longitudinal dimension of the body flap226can be selectively reduced by folding or tearing off the length sections232a′,232b′ and234a′,234b′ as described above for the blank10. The portions232c,234cof the lateral flap fold line230adjacent to the ends of the length sections232a′,232b′,234a′,234b′ can be formed with perforations or through cuts sufficient to facilitate separation of the length sections232a′,232b′,234a′,234b′ from the central panel224, whereas the remainder of the flap fold line230may be formed as a crease rule fold line, i.e., a non-separating fold line.

It may be noted that the number and location of length score lines illustrated for the first body flap226is not limited to the particular length score lines232a,232b,234a,234billustrated herein. For example, an additional length score line232d,234dmay be provided subdividing each of the respective length sections232a′,234a′ into additional length sections232a1′,232a2′ and234a1′,234a2′, wherein the additional length score lines232d,234dcan facilitate selection of a length for the beam246to fit within and provide support in a space between adjacent pallets and/or truck sides. Further it may be understood that additional length score lines (not shown) may be provided, such as to subdivide the length sections232b′,234b′, and the relative width of the length sections232a′,232b′,234a′,234b′ and232a1′,232a2′,234a1′,234a2′ can be different than is illustrated herein.

The first body flap226can further include a support structure comprising a first support flap271configured to extend between two opposing panels forming the first beam body246. In the illustrated embodiment, the support flap271is formed in the second flap panel252band is defined by opposing side separation lines271a,271bsubstantially aligned along the first and second panel fold lines254a,254b, and an end separation line271cextending between the side separation lines271a,271b. A support flap fold line271dcan be defined opposite from the end separation line271cextending between the side separation lines271a,271b. In addition, a finger notch or slot271ecan be formed in the first support flap271adjacent to the end separation line271c. It may be understood that the first support flap271defines a width that is substantially the same as a width of the first beam body246, as defined between the first and third flap panels252a,252c. Further, the first support flap271can comprise a length, extending from the end separation line271cto the support flap fold line271dthat is greater than half the distance from the first panel fold line254ato the first flap fold line230and/or half the distance from the second panel fold line254bto the third panel fold line254c. Alternatively, the first support flap271can comprise a length that is shorter or longer than is depicted herein.

The second body flap228comprises a first flap panel256a, a second flap panel256b, a third flap panel256c, and a glue tab256dconnected in series at a first panel fold line258a, a second panel fold line258b, and a third panel fold line258c, respectively. The first, second, and third panel fold lines258a,258b,258cmay comprise crease rule fold lines. The glue tab256dcan be formed with a relatively short lateral dimension, i.e., relative to the lateral dimensions of the flap panels256a,256b,256c, and can form an attachment structure for attaching a laterally outer end of the third flap panel256cto the central panel224when the body flap228is erected to form the beam body248, as discussed further below.

The second flap fold line240is defined at a connection between the first flap panel256aand the central panel224, wherein the second flap fold line240is located laterally spaced inward from the second lateral side portions222a1,222a2. At least a portion of the flap fold line240can comprise a crease rule fold line. A pair of separation lines262a,262bextend laterally along the inner longitudinal edges242,244from the second flap fold line240to the second lateral side portions222a1,222a2, separating the second body flap228from the central panel224and permitting pivotal movement of the second body flap228within the central panel224.

The second body flap228can also include one or more length score lines242a,242band244a,244bextending parallel to the respective longitudinal edges242,244and defining respective length sections242a′,242b′ and244a′,244b′. The edges of the body flap228can be folded, or alternatively torn off, at the length score lines242a,242band244a,244bto shorten the beam length defined by the body flap228. The longitudinal dimension of the body flap228can be selectively reduced by folding or tearing off the length sections242a′,242b′ and244a′,244b′ as described above for the blank10. The portions242c,244cof the lateral flap fold line240adjacent to the ends of the length sections242a′,242b′,244a′,244b′ can be formed with perforations or through cuts sufficient to facilitate separation of the length sections242a′,242b′,244a′,244b′ from the central panel224, whereas the remainder of the flap fold line240may be formed as a crease rule fold line, i.e., a non-separating fold line.

It may be noted that the number and location of length score lines illustrated for the second body flap228is not limited to the particular length score lines242a,242b,244a,244billustrated herein. For example, an additional length score line242d,244dmay be provided subdividing each of the respective length sections242a′,244a′ into additional length sections242a1′,242a2′ and244a1′,244a2′, wherein the additional length score lines242d,244dcan facilitate selection of a length for the beam248to fit within and provide support in a space between adjacent pallets and/or truck sides. Further it may be understood that additional length score lines (not shown) may be provided, such as to subdivide the length sections242b′,244b′. Also, the relative width of the length sections242a′,242b′,244a′,244b′ and242a1′,242a2′,244a1′,244a2′ can be different than is illustrated herein.

It may be noted that the length score lines232a,232b,234a,234band242a,242b,244a,244b, of the first and second body flaps226,228can be formed as perforated lines extending fully or partially through the blank210for facilitating either folding or tearing, i.e. separating, the respective length sections232a′,232b′,234a′,234b′ and242a′,242b′,244a′,244b′. Similarly, the length score lines232d,234dand242d,244dcan be formed as perforated lines extending fully or partially through the blank210for facilitating either folding or tearing, i.e. separating, the respective length sections232a1′,232a2′,234a1′,234a2′ and242a1′,242a2′,244a2′.

The second body flap228can further include a support structure comprising a second support flap273configured to extend between two opposing panels forming the second beam body248. In the illustrated embodiment, the support flap273is formed in the second flap panel256band is defined by opposing side separation lines273a,273bsubstantially aligned along the first and second panel fold lines258a,258b, and an end separation line273cextending between the side separation lines273a,273b. A support flap fold line273dcan be defined opposite from the end separation line273cextending between the side separation lines273a,273b. In addition, a finger notch or slot273ecan be formed in the second support flap273adjacent to the end separation line273c. It may be understood that the second support flap273defines a width that is substantially the same as a width of the second beam body248, as defined between the first and third flap panels256a,256c. Further, the second support flap273can comprise a length, extending from the end separation line273cto the support flap fold line273dthat is greater than half the distance from the first panel fold line258ato the second flap fold line240and/or half the distance from the second panel fold line258bto the third panel fold line258c. Alternatively, the second support flap273can comprise a length that is shorter or longer than is depicted herein.

The first, second, and third flap panels252a,252b,252cand256a,256b,256cof the respective body flaps226and228can generally be folded as described above for the body flaps26,28of the blank10to form the beam bodies246,248of the hollow beam structure250, seeFIGS. 12 and 13. The glue tabs252d,256dcan be attached, e.g., via glued joints between the glue tabs252d,256dand the central panel224, extending in overlapping relation parallel to the central panel224. In an erected configuration of the beam bodies246,248, the glue tabs252d,256dcan extend outwardly from the respective third panel flaps252c,256c, i.e., extending toward each other and toward a lateral center of the central panel224.

In an exemplary use of the blank210, an outer portion of each of the body flaps226,228located laterally outwardly from the respective first panel fold lines254a,258a, i.e., the second and third panel flaps252b,252cand256b,256c, can be folded inwardly toward the central panel224, overlapping the respective first panel flaps252a,256aand locating the glue tabs252d,256dat the locations on the central panel224shown inFIG. 11. The glue tabs252d,256dmay be attached to the central panel224at a manufacturer's joint to define a knocked down or collapsed configuration that can be provided to a user. The user can erect the pallet stabilizer by pivoting the pairs of first and third panel flaps252a,252cand256a,256cparallel to each other and transverse, e.g., perpendicular, to the central panel224to form up each of the beam bodies246,248into a parallelepiped configuration. The support flaps271,273can be pivoted into the respective beam bodies246,248, and positioned transverse, e.g., perpendicular, to the second panel flaps252b,256b, as depicted inFIGS. 12 and 13. In the pivoted position, the support flaps271,273can frictionally engage the opposing pairs of first and third panel flaps252a,252cand256a,256cto maintain the support flaps271,273in position and provide lateral support to the beam bodies246,248, substantially preventing or resisting the beam bodies246,248from moving to the collapsed position.

The first beam side of the first beam body246, defined by the first flap panel252a, can be spaced laterally inward from the first lateral side220adefined by the first and second lateral side portions220a1,220a2, such that a first pair of lateral extensions264a,264bare defined on the central panel224, seeFIGS. 10 and 12. Similarly, the first beam side of the second beam body248, defined by the first flap panel256a, can be spaced laterally inward from the second lateral side222adefined by the first and second lateral side portions222a1,222a2, such that a second pair of lateral extensions266a,266bare defined on the central panel224.

The lateral extensions264a,266acomprise laterally opposing ends of a first support member268athat extends longitudinally outward from first longitudinal ends of the first and second beam bodies246,248. The lateral extensions264b,266bcomprise laterally opposing ends of a second support member268bthat extends longitudinally outward from second longitudinal ends of the first and second beam bodies246,248. Hence, the ends of the beam bodies246,248are located longitudinally inward from the respective first and second longitudinal sides216a,218aof the central panel224.

It should be understood that aspects of the pallet stabilizer208described with reference toFIGS. 10-13can be incorporated in a pallet stabilizer configuration formed from a blank having a single body flap, such as is described above for the pallet stabilizer110with reference toFIGS. 8 and 9. For example, the pallet stabilizer208may be constructed with a single beam body, e.g., beam body246, supported at a generally central lateral location on the central panel224, e.g., in a manner similar to the construction described for the pallet stabilizer110with reference toFIGS. 8 and 9.