# Patent

## Title
Method and apparatus for palletizing a product

## Abstract

A corrugate palletized container is provided that includes a base defining at least one channel, the channel operable to accept a lifting device therein and a plurality of side walls extending from the base, the plurality of side walls defining a storage space between them.

## Background
BACKGROUND
The present disclosure relates generally to shipping containers, and more particularly to a method and apparatus for palletizing a product to be shipped.
Products that weigh over a certain amount raise a number of issues with regards to transporting those products. A high weight product typically requires that the product be attached to a pallet in order to allow for mechanical lifting of the product by a machine such as, for example, a forklift. Generally, a box is attached to a pallet by straps and/or fasteners, and the product is placed in the box when it is ready to be shipped. The pallets are generally made of wood to reduce cost and allow easy attachment of the box to the pallet.
However, freight costs for shipping the product are determined based on the weight of the combined product, box, and pallet. Wooden pallets and the components necessary to attach the box to the pallet increase the weight of the combination, increasing the cost of shipping the product.
Furthermore, the box and pallet must be lifted by factory operators in order to position the box on a conveyor or some other means which will position the box appropriately such that the product may be placed in it. The additional weight of the wooden pallet and components necessary to attach the box to the pallet may be lifted several hundreds of times per day, creating ergonomic issues with the factory operators.
Finally, in order to ship products overseas, wooden pallets must be treated to ensure they do not carry bugs. Products attached to wooden pallets may be held up during overseas transportation or rejected all together due to possible bug issues with the wooden pallets.
Accordingly, it would be desirable to provide an improved method and apparatus for palletizing a product absent the disadvantages found in the prior methods discussed above.
SUMMARY
According to one embodiment, a corrugate palletized container is provided that includes a base defining at least one channel, the channel operable to accept a lifting device therein, and a plurality of side walls extending from the base, the plurality of side walls defining a storage space between them.
A principal advantage of this embodiment is that a product may be shipped in the corrugate palletized container with a weight reduction from standard shipping methods that reduces shipping costs and ergonomic issues with respect to lifting the container. Furthermore, the corrugate material reduces issues related to bugs that can complicate overseas shipping.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view illustrating an exemplary embodiment of an unassembled pallet container.
FIG. 2 is a perspective view illustrating an exemplary embodiment of a interior reinforcement member used with the pallet container of FIG. 1.
FIG. 3 is a perspective view illustrating an exemplary embodiment of an exterior reinforcement member used with the pallet container of FIG. 1.
FIG. 4 is a perspective view illustrating an exemplary embodiment of a support panel used with the pallet container of FIG. 1.
FIG. 5 is a perspective view illustrating an exemplary embodiment of a cover panel used with the pallet container of FIG. 1.
FIG. 6 is a perspective view illustrating an exemplary embodiment of a base support used with the pallet container of FIG. 1.
FIG. 7a is a perspective view illustrating an exemplary embodiment of the pallet container of FIG. 1 partially assembled.
FIG. 7b is a cut-away perspective view illustrating an exemplary embodiment of the pallet container of FIG. 1 assembled.
FIG. 8 is a perspective view illustrating an exemplary embodiment of the pallet container of FIG. 7b including a plurality of the base supports of FIG. 6.
FIG. 9a is a cut-away perspective view illustrating an exemplary embodiment of the pallet container of FIG. 8 including a plurality of the interior reinforcement members of FIG. 2.
FIG. 9b is a cut-away perspective view illustrating an exemplary embodiment of the pallet container of FIG. 9a including a plurality of the exterior reinforcement members of FIG. 3.
FIG. 10 is a cut-away perspective view illustrating an exemplary embodiment of the pallet container of FIG. 9b including the support panel of FIG. 4.
FIG. 11 is a cut-away perspective view illustrating an exemplary embodiment of the pallet container of FIG. 10 including the cover panel of FIG. 5.
FIG. 12 is a perspective view illustrating an exemplary embodiment of the pallet container of FIG. 11 including a product in the storage space.
FIG. 13 is a front view illustrating an exemplary embodiment of a pallet container.
FIG. 14 is a perspective view illustrating an exemplary embodiment of the pallet container of FIG. 13 partially assembled.



DETAILED DESCRIPTION
In an exemplary embodiment, as illustrated in FIG. 1, a pallet container 100 includes a single piece of material including a plurality of base portions 102a and 102b. Base portion 102a includes a plurality of tabs 102aa, 102ab, 102ac, 102ad, 102ae, and 102af extending from the base portion 102a in a spaced apart relationship on opposite sides of the base portion 102a. Base portion 102a may be perforated along lines 102ag and 102ah which are positioned between tabs 102aa, 102ab, 102ad, and 102ae and run parallel to each other. Base portion 102a may also be perforated along lines 102ai and 102aj which are positioned between tabs 102ab, 102ac, 102ae, and 102af and run parallel to each other. Base portion 102b includes a plurality of tabs 102ba, 120bb, 102bc, and 102bd extending from the base portion 102b in a spaced apart relationship on opposite sides of the base portion 102b. Base portion 102b may be perforated along lines 102be and 102bf which are positioned between tabs 102ba, 102bb, 102bc, and 102bd and run parallel to each other. Base portion 102b may also be perforated along lines 102bg and 102bh which are positioned adjacent tabs 102bb and 102bd and run parallel to each other.
A plurality of side walls 104a, 104b, 104c, and 104d extend from the base portions 102a and 102b due to the extension of side wall 104a from base portion 102a and the extension of side wall 104c from base portion 102b. Side wall 104b extends between side walls 104a and 104c, and side wall 104d extends from side wall 104c. Side wall 104a is bendably coupled to the base portion 102a and includes a tab 104aa extending from it. Side wall 104b is bendably coupled to side wall 104a and side wall 104c and defines a plurality of channel inlet/outlets 104ba and 104bb on its edge. Side wall 104c is bendably coupled to side wall 104b, base portion 102b, and side wall 104d. Side wall 104d is bendably coupled to side wall 104c and defines a plurality of channel inlet/outlets 104da and 104db on its edge.
A plurality of top portions 106a, 106b, 106c, and 106d extend from side walls 104a, 104b, 104c, and 104d, respectively. Top portion 106a is bendably coupled to side wall 104a. Top portion 106b is bendably coupled to side wall 104b. Top portion 106c is bendably coupled to side wall 104c. Top portion 106d is bendably coupled to side wall 104d. 
In an exemplary embodiment, the pallet container 100 may be comprised of a variety of materials such as, for example, cardboards, corrugates, plastics, or other equivalent materials known in the art.
Referring now to FIG. 2, an interior reinforcement member 200 is illustrated and includes a top 202 and a bottom 204 which are spaced apart and coupled together by a plurality of vertical structural members 206. In an exemplary embodiment, the interior reinforcement member 200 may be comprised of a variety of materials such as, for example, cardboards, corrugates, plastics, or other equivalent materials known in the art. In an exemplary embodiment, the vertical structural members 206 may be made of the same material as the top 202 and bottom 204 and may be positioned such that they have a honeycomb cross-section.
Referring now to FIG. 3, an exterior reinforcement member 300 is illustrated and includes a base 302 and a plurality of arms 304 and 306 extending from opposite edges of the base 302 and along its length such that the member 300 has a substantially U-shaped cross section. In an exemplary embodiment, the exterior reinforcement member 300 may be comprised of a variety of materials such as, for example, cardboards, corrugates, plastics, or other equivalent materials known in the art.
Referring now to FIG. 4, a support panel 400 is illustrated and includes a substantially square piece of material with a top surface 402, a bottom surface 404 opposite the top surface 402, and a plurality of opposing sides 406 and 408. In an exemplary embodiment, the support panel 400 may be comprised of a variety of materials such as, for example, cardboards, corrugates, plastics, or other equivalent materials known in the art.
Referring now to FIG. 5, a cover panel 500 is illustrated and includes a base 502 including a top surface 502a and a bottom surface 502b opposite the top surface 502a. A plurality of arms 504 and 506 extend from opposite edges of the base 502 and along its length. In an exemplary embodiment, the cover panel 500 may be comprised of a variety of materials such as, for example, cardboards, corrugates, plastics, or other equivalent materials known in the art.
Referring now to FIG. 6, a base support 600 includes an elongated member 602 having a top surface 604 and a bottom surface 606 opposite the top surface 604. In an exemplary embodiment, the base support 600 may be comprised of a variety of materials such as, for example, cardboards, corrugates, plastics, or other equivalent materials known in the art.
Referring now to FIGS. 1, 6, 7a and 7b, in assembly operation, pallet container 100 begins assembly by bending base portion 102a with respect to side wall 104a until the two are at approximately a ninety degree angle, as illustrated in FIG. 7a. Side wall 104a may then be bent at approximately a ninety degree angle with respect to side wall 104b. Base portion 102a may then be bent at approximately ninety degree angles along perforated lines 102ag, 102ah, 102ai, and 102aj such that the edge of base portion 102a including tabs 102ad, 102ae, and 102af to run substantially along the edges of channel inlet/outlet 104ba on side wall 104b. Tabs 102ad, 102ae and 102af may then be bent at approximately ninety degree angles with respect to base portion 102a such that they may be secured to side wall 104b by glue, staples, or other conventional securing means known in the art.
Base portion 102b is bent with respect to side wall 104c until the two are at approximately a ninety degree angle. Side wall 104c may then be bent at approximately a ninety degree with respect to side wall 104b. Base portion 102b may then be bent at approximately ninety degree angles along perforated lines 102be, 102bf, 102bg, and 102bh such that the edge of base portion 102b including tabs 102ba and 102bb to run substantially along the edges of channel inlet/outlet 104bb on side wall 104b. Tabs 102ba and 102bb may then be bent at approximately ninety degree angles with respect to base portion 102b such that they may be secured to side wall 104b by glue, staples, or other conventional securing means known in the art.
Base portion 104d is bent with respect to side wall 104c until the two are at approximately a ninety degree angle, such that the edge of base portion 102b including tabs 102bc and 102bd running along the edge of channel outlet 104da, and the edge of base portion 102a including tabs 102aa, 102ab and 102ac runs along the edge of channel inlet/outlet 104db. Tabs 102aa, 102ab, and 102ac may then be bent at approximately ninety degree angles with respect to base portion 102a, and tabs 102bd and 102bc may then be bent at approximately ninety degree angles with respect to base portion 102b, such that the tabs 102aa, 102ab, 102ac, 102bd and 102bc may be secured to side wall 104d by glue, staples, or other conventional securing means known in the art. Tab 104aa is bent at approximately a ninety degree angle with respect to side wall 104a such that it may be secured to side wall 104d by glue, staples, or other convention securing means known in the art. Pallet container 100 now defines a plurality of channels 700a and 700b, with channel 700a running along a width of pallet container 100 and including channel inlet/outlets 104ba and 104da, and with channel 700b running parallel to channel 700a and along a length of pallet container 100 and including channel inlet/outlets 104bb and 104db. Side walls 104a, 104b, 104c, and 104d now define a storage space 702 positioned between them. In several exemplary embodiments, the pallet container 100 may be assembled using a variety of equivalent alternative means known in the art and therefore may not includes features such as, for example, tabs 102aa, 102ab, 102ac, 102ad, 102ae, 102af, 102ba, 102bb, 102bc, and 102bd. 
Referring now to FIG. 8, the top surface 604 of a base support 600 is secured to the pallet container 100 adjacent the channel inlet/outlets 104da and 104db and substantially perpendicular to the channels 700a and 700b. The base support 600 may be secured to the pallet container 100 by glue, staples, or other convention securing means known in the art. The top surface 604 of a base support 600 is also secured to the pallet container 100 adjacent the channel inlet/outlets 104ba and 104bb (not shown), substantially perpendicular to the channels 700a and 700b and substantially parallel to the other base support 600. The base supports 600 may be secured to the pallet container 100 by glue, staples, or other convention securing means known in the art.
Referring now to FIG. 2, 3, 9a and 9b, a plurality of interior reinforcement members 200 are positioned in the storage space 702, extending along the length of channels 700a and 700b and on opposite sides of each channel 700a and 700b. In an exemplary embodiment, when positioned in the storage space 702, the top 202 of each interior reinforcement member 200 is substantially the same height at the channel 700a or 700b. A plurality of exterior reinforcement members 300 are positioned in the channels 700a and 700b and the bases 302 and arms 304 and 306 are secured to the walls of the channels 700a and 700b by glue, staples, or a variety of other conventional securing means known in the art.
Referring now to FIGS. 4, 9a, 9b and 10, support panel 400 is positioned in the storage space 702 such that bottom surface 404 of support panel 400 engages sections of base portions 102a and 102b that define channels 700a and 700b and the top 202 of the interior reinforcement member 200 positioned between channels 700a and 700b. In an exemplary embodiment, side 406 of support panel 400 is adjacent an edge of channel 700a and side 408 of support panel 400 is adjacent an edge of channel 700b when the support panel 400 is positioned in storage space 702.
Referring now to FIG. 5, 10 and 11, cover panel 500 is positioned in storage space 702 such that bottom surface 502b of base 502 engages top surface 402 of support panel 400 and the tops 202 of the interior reinforcement members 200 not engaged by support panel 400, and arms 504 and 506 engage side walls 104a and 104c. 
Referring now to FIG. 12, a product 800 may be positioned in the storage space 702 for shipping. In an exemplary embodiment, product 800 may be a server, an information handling system, or a variety of other products known in the art. Top portions 106a, 106b, 106c, and 106d (not shown) may then be closed, and the pallet container 100 may be lifted by placing a lifting device in the channels 700a and 700b and lifting the pallet container 100 and placing it in an appropriate vehicle for shipping.
Referring now to FIG. 13, an alternative embodiment of a pallet container 900 is substantially identical in design and operation to pallet container 100 described above with reference to FIGS. 1, 2, 3, 4, 5, 6, 7a, 7b, 8, 9a, 9b, 10, 11, and 12 with the addition of a modified single piece of material including a plurality of base portions 902a, 902b, 902c, and 902d. Base portion 902a is perforated along lines 902aa, 902ab, 902ac, and 902ad, all which run parallel to each other. A plurality of tabs 902ae and 902af are positioned on opposite sides of base portion 902a. Base portion 902b is positioned adjacent to base portion 902a and is perforated along lines 902ba and 902bb, which run parallel to each other. Base portion 902c is positioned adjacent base portion 902b and is perforated along lines 902ca, 902cb, 902cc, and 902cd, all which run parallel to each other. A plurality of tabs 902ce and 902cf are positioned on opposite sides of base portion 902c. Base portion 902d is positioned adjacent to base portion 902c and is perforated along lines 902da and 902db, which run parallel to each other.
A plurality of side walls 904a, 904b, 904c, and 904d extend from, and are bendably coupled to, the base portions 902a, 902b, 902c, and 902d, respectively. Side wall 904a defines a plurality of channel inlets/outlets 904aa and 904ab on its edge. Side wall 904b extends between, and is bendably coupled to, side walls 904a and 904c. Side wall 904c defines a plurality of channel inlets/outlets 904ca and 904cb on its edge. Side wall 904d extends from, and is bendably coupled to, side wall 904c. A tab 904da extends from side wall 904d. 
A plurality of top portions 906a, 906b, 906c, and 906d extend from side walls 904a, 904b, 904c, and 904d, respectively. Top portion 906a is bendably coupled to side wall 904a. Top portion 906b is bendably coupled to side wall 904b. Top portion 906c is bendably coupled to side wall 904c. Top portion 906d is bendably coupled to side wall 904d. 
Referring now to FIGS. 13 and 14, in assembly operation, pallet container 900 begins assembly by bending base portion 902a with respect to side wall 904a until the two are at approximately a ninety degree angle. Base portion 902a then be bent at approximately ninety degree angles along lines 902aa, 902ab, 902ac and 902ad such that an edge of base portion 902a runs along portions of channel inlets/outlets 904aa and 904ab. Tabs 902ae and 902af may be bent at approximately ninety degree angles with respect to side wall 904a. Side wall 904b may then be bent with respect to side wall 904a until the two are at approximately a ninety degree angle. Base portion 902b may then be bent at approximately ninety degree angles along lines 902ba and 902bb such that an edge of base portion 902bruns along a portion of channel inlet/outlet 904ba, with tab 902af positioned between side wall 904b and line 902bb. 
Base portion 902c is then bent with respect to side wall 904c until the two are at approximately a ninety degree angle. Base portion 902c then be bent at approximately ninety degree angles along lines 902ca, 902cb, 902cc and 902cd such that an edge of base portion 902c runs along portions of channel inlets/outlets 904ca and 904cb. Tabs 902ce and 902cf may be bent at approximately ninety degree angles with respect to side wall 904a. Side wall 904d may then be bent with respect to side wall 904c until the two are at approximately a ninety degree angle. Base portion 902d may then be bent at approximately ninety degree angles along lines 902da and 902db such that an edge of base portion 902d runs along a portion of channel inlet/outlet 904ca, with tab 902cf positioned between side wall 904d and line 902db. 
Side wall 904c is then bent with respect to side wall 904b until the two are at approximately a ninety degree angle. Tab 902ce may then be positioned between side wall 904b and line 902bb with an edge of base portion 902b running along a portion of channel inlet/outlet 904cb, and tab 902ae may be positioned between side wall 904d and line 902db with an edge of base portion 902d running along a portion of channel inlet/outlet 904aa. In an exemplary embodiment, tab 904da may be secured to side wall 904a using glue, staples, or other conventional securing means known in the art. In an exemplary embodiment, tab 904ae may be secured to tab 902cf using glue, staples, or other conventional securing means known in the art. In an exemplary embodiment, tab 904af may be secured to tab 904ce using glue, staples, or other conventional securing means known in the art. In an exemplary embodiment, base portion 902a may be secured to base portion 902b using glue, staples, or other conventional securing means known in the art. In an exemplary embodiment, base portion 902a may be secured to base portion 902c using glue, staples, or other conventional securing means known in the art. In an exemplary embodiment, base portion 902a may be secured to base portion 902d using glue, staples, or other conventional securing means known in the art. In an exemplary embodiment, base portion 902c may be secured to base portion 902b using glue, staples, or other conventional securing means known in the art. In an exemplary embodiment, base portion 902c may be secured to base portion 902d using glue, staples, or other conventional securing means known in the art. Further assembly of pallet container 900 is substantially similar to the assembly of pallet container 100 as illustrated above with reference to FIGS. 8, 9a, 9b, 10, 11, and 12.
It is understood that variations may be made in the foregoing without departing from the scope of the invention. Furthermore, the elements and teachings of the various illustrative embodiments may be combined in whole or in part some or all of the illustrative embodiments.
Although illustrative embodiments have been shown and described, a wide range of modification, change and substitution is contemplated in the foregoing disclosure and in some instances, some features of the embodiments may be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the embodiments disclosed herein.

## Claims

1. A corrugate palletized container comprising:
a foldable single piece of material comprising plural side wall panels, plural top panels and plural bottom panels, the bottom panels forming a plurality of channels between a plurality of reinforcing portions, the material being folded to form a container;
a separate reinforcing member in each of the reinforcing portions;
a separate reinforcing insert in each channel;
a separate first reinforcing panel adjacent the channels and the reinforcing portions;
a separate second reinforcing panel adjacent the first reinforcing panel, the second reinforcing panel having a plurality of arms inserted between opposite ones of the side walls and the reinforcing members; and
at least one separate exterior base reinforcing member.

2. The container of claim 1 wherein each reinforcing member includes a honeycomb cross-section.

3. The container of claim 1 wherein each reinforcing member includes a pair of base members coupled together by a honeycomb member.

4. The container of claim 1 wherein the plurality of channels comprise a pair of parallel channels, the pair of parallel channel operable to receive a forked lifting device therein.

5. A method for palletizing a product comprising:
providing a foldable single piece of corrugate material comprising plural side wall panels, plural top panels and plural bottom panels, the bottom panels forming a plurality of channels between a plurality of reinforcing portions, the material being folded to form a palletized container;
inserting a separate reinforcing member in each of the reinforcing portions;
placing a separate reinforcing insert in each channel;
placing a separate first reinforcing panel adjacent the channels and the reinforcing portions;
placing a separate second reinforcing panel adjacent the first reinforcing panel, the second reinforcing panel having a plurality of arms inserted between opposite ones of the side walls and the reinforcing members; and
attaching at least one separate exterior base reinforcing member.

6. The method of claim 5, further comprising:
placing a product in the container.

7. The method of claim 6, further comprising:
folding the top panels to enclose the product in the container.

8. The method of claim 5, further comprising:
providing each reinforcing member with a pair of base members coupled together by a honeycomb member.