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.

Description:
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. 7   a  is a perspective view illustrating an exemplary embodiment of the pallet container of  FIG. 1  partially assembled. 
       FIG. 7   b  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. 7   b  including a plurality of the base supports of  FIG. 6 . 
       FIG. 9   a  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. 9   b  is a cut-away perspective view illustrating an exemplary embodiment of the pallet container of  FIG. 9   a  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  102   a  and  102   b . Base portion  102   a  includes a plurality of tabs  102   aa ,  102   ab ,  102   ac ,  102   ad ,  102   ae , and  102   af  extending from the base portion  102   a  in a spaced apart relationship on opposite sides of the base portion  102   a . Base portion  102   a  may be perforated along lines  102   ag  and  102   ah  which are positioned between tabs  102   aa ,  102   ab ,  102   ad , and  102   ae  and run parallel to each other. Base portion  102   a  may also be perforated along lines  102   ai  and  102   aj  which are positioned between tabs  102   ab ,  102   ac ,  102   ae , and  102   af  and run parallel to each other. Base portion  102   b  includes a plurality of tabs  102   ba ,  120   bb ,  102   bc , and  102   bd  extending from the base portion  102   b  in a spaced apart relationship on opposite sides of the base portion  102   b . Base portion  102   b  may be perforated along lines  102   be  and  102   bf  which are positioned between tabs  102   ba ,  102   bb ,  102   bc , and  102   bd  and run parallel to each other. Base portion  102   b  may also be perforated along lines  102   bg  and  102   bh  which are positioned adjacent tabs  102   bb  and  102   bd  and run parallel to each other. 
   A plurality of side walls  104   a ,  104   b ,  104   c , and  104   d  extend from the base portions  102   a  and  102   b  due to the extension of side wall  104   a  from base portion  102   a  and the extension of side wall  104   c  from base portion  102   b . Side wall  104   b  extends between side walls  104   a  and  104   c , and side wall  104   d  extends from side wall  104   c . Side wall  104   a  is bendably coupled to the base portion  102   a  and includes a tab  104   aa  extending from it. Side wall  104   b  is bendably coupled to side wall  104   a  and side wall  104   c  and defines a plurality of channel inlet/outlets  104   ba  and  104   bb  on its edge. Side wall  104   c  is bendably coupled to side wall  104   b , base portion  102   b , and side wall  104   d . Side wall  104   d  is bendably coupled to side wall  104   c  and defines a plurality of channel inlet/outlets  104   da  and  104   db  on its edge. 
   A plurality of top portions  106   a ,  106   b ,  106   c , and  106   d  extend from side walls  104   a ,  104   b ,  104   c , and  104   d , respectively. Top portion  106   a  is bendably coupled to side wall  104   a . Top portion  106   b  is bendably coupled to side wall  104   b . Top portion  106   c  is bendably coupled to side wall  104   c . Top portion  106   d  is bendably coupled to side wall  104   d.    
   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  502   a  and a bottom surface  502 b opposite the top surface  502   a . 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 ,  7   a  and  7   b , in assembly operation, pallet container  100  begins assembly by bending base portion  102   a  with respect to side wall  104   a  until the two are at approximately a ninety degree angle, as illustrated in  FIG. 7   a . Side wall  104   a  may then be bent at approximately a ninety degree angle with respect to side wall  104   b . Base portion  102   a  may then be bent at approximately ninety degree angles along perforated lines  102   ag ,  102   ah ,  102   ai , and  102   aj  such that the edge of base portion  102   a  including tabs  102   ad ,  102   ae , and  102   af  to run substantially along the edges of channel inlet/outlet  104   ba  on side wall  104   b . Tabs  102   ad ,  102   ae  and  102   af  may then be bent at approximately ninety degree angles with respect to base portion  102   a  such that they may be secured to side wall  104   b  by glue, staples, or other conventional securing means known in the art. 
   Base portion  102   b  is bent with respect to side wall  104   c  until the two are at approximately a ninety degree angle. Side wall  104   c  may then be bent at approximately a ninety degree with respect to side wall  104   b . Base portion  102   b  may then be bent at approximately ninety degree angles along perforated lines  102   be ,  102   bf ,  102   bg , and  102   bh  such that the edge of base portion  102   b  including tabs  102   ba  and  102   bb  to run substantially along the edges of channel inlet/outlet  104   bb  on side wall  104   b . Tabs  102   ba  and  102   bb  may then be bent at approximately ninety degree angles with respect to base portion  102   b  such that they may be secured to side wall  104   b  by glue, staples, or other conventional securing means known in the art. 
   Base portion  104   d  is bent with respect to side wall  104   c  until the two are at approximately a ninety degree angle, such that the edge of base portion  102   b  including tabs  102   bc  and  102   bd  running along the edge of channel outlet  104   da , and the edge of base portion  102   a  including tabs  102   aa ,  102   ab  and  102   ac  runs along the edge of channel inlet/outlet  104   db . Tabs  102   aa ,  102   ab , and  102   ac  may then be bent at approximately ninety degree angles with respect to base portion  102   a , and tabs  102   bd  and  102   bc  may then be bent at approximately ninety degree angles with respect to base portion  102   b , such that the tabs  102   aa ,  102   ab ,  102   ac ,  102   bd  and  102   bc  may be secured to side wall  104   d  by glue, staples, or other conventional securing means known in the art. Tab  104   aa  is bent at approximately a ninety degree angle with respect to side wall  104   a  such that it may be secured to side wall  104   d  by glue, staples, or other convention securing means known in the art. Pallet container  100  now defines a plurality of channels  700   a  and  700   b , with channel  700   a  running along a width of pallet container  100  and including channel inlet/outlets  104   ba  and  104   da , and with channel  700   b  running parallel to channel  700   a  and along a length of pallet container  100  and including channel inlet/outlets  104   bb  and  104   db . Side walls  104   a ,  104   b ,  104   c , and  104   d  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  102   aa ,  102   ab ,  102   ac ,  102   ad ,  102   ae ,  102   af ,  102   ba ,  102   bb ,  102   bc , and  102   bd.    
   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  104   da  and  104   db  and substantially perpendicular to the channels  700   a  and  700   b . 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  104   ba  and  104   bb  (not shown), substantially perpendicular to the channels  700   a  and  700   b  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 ,  9   a  and  9   b , a plurality of interior reinforcement members  200  are positioned in the storage space  702 , extending along the length of channels  700   a  and  700   b  and on opposite sides of each channel  700   a  and  700   b . 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  700   a  or  700   b . A plurality of exterior reinforcement members  300  are positioned in the channels  700   a  and  700   b  and the bases  302  and arms  304  and  306  are secured to the walls of the channels  700   a  and  700   b  by glue, staples, or a variety of other conventional securing means known in the art. 
   Referring now to  FIGS. 4 ,  9   a ,  9   b  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  102   a  and  102   b  that define channels  700   a  and  700   b  and the top  202  of the interior reinforcement member  200  positioned between channels  700   a  and  700   b . In an exemplary embodiment, side  406  of support panel  400  is adjacent an edge of channel  700   a  and side  408  of support panel  400  is adjacent an edge of channel  700   b  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  502   b  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  104   a  and  104   c.    
   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  106   a ,  106   b ,  106   c , and  106   d  (not shown) may then be closed, and the pallet container  100  may be lifted by placing a lifting device in the channels  700   a  and  700   b  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 ,  7   a ,  7   b ,  8 ,  9   a ,  9   b ,  10 ,  11 , and  12  with the addition of a modified single piece of material including a plurality of base portions  902   a ,  902   b ,  902   c , and  902   d . Base portion  902   a  is perforated along lines  902   aa ,  902   ab ,  902   ac , and  902   ad , all which run parallel to each other. A plurality of tabs  902   ae  and  902   af  are positioned on opposite sides of base portion  902   a . Base portion  902   b  is positioned adjacent to base portion  902   a  and is perforated along lines  902   ba  and  902   bb , which run parallel to each other. Base portion  902   c  is positioned adjacent base portion  902   b  and is perforated along lines  902   ca ,  902   cb ,  902   cc , and  902   cd , all which run parallel to each other. A plurality of tabs  902   ce  and  902   cf  are positioned on opposite sides of base portion  902   c . Base portion  902   d  is positioned adjacent to base portion  902   c  and is perforated along lines  902   da  and  902   db , which run parallel to each other. 
   A plurality of side walls  904   a ,  904   b ,  904   c , and  904   d  extend from, and are bendably coupled to, the base portions  902   a ,  902   b ,  902   c , and  902   d , respectively. Side wall  904   a  defines a plurality of channel inlets/outlets  904   aa  and  904   ab  on its edge. Side wall  904   b  extends between, and is bendably coupled to, side walls  904   a  and  904   c . Side wall  904   c  defines a plurality of channel inlets/outlets  904   ca  and  904   cb  on its edge. Side wall  904   d  extends from, and is bendably coupled to, side wall  904   c . A tab  904   da  extends from side wall  904   d.    
   A plurality of top portions  906   a ,  906   b ,  906   c , and  906   d  extend from side walls  904   a ,  904   b ,  904   c , and  904   d , respectively. Top portion  906   a  is bendably coupled to side wall  904   a . Top portion  906   b  is bendably coupled to side wall  904   b . Top portion  906   c  is bendably coupled to side wall  904   c . Top portion  906   d  is bendably coupled to side wall  904   d.    
   Referring now to  FIGS. 13 and 14 , in assembly operation, pallet container  900  begins assembly by bending base portion  902   a  with respect to side wall  904   a  until the two are at approximately a ninety degree angle. Base portion  902   a  then be bent at approximately ninety degree angles along lines  902   aa ,  902   ab ,  902   ac  and  902   ad  such that an edge of base portion  902   a  runs along portions of channel inlets/outlets  904   aa  and  904   ab . Tabs  902   ae  and  902   af  may be bent at approximately ninety degree angles with respect to side wall  904   a . Side wall  904   b  may then be bent with respect to side wall  904   a  until the two are at approximately a ninety degree angle. Base portion  902   b  may then be bent at approximately ninety degree angles along lines  902   ba  and  902   bb  such that an edge of base portion  902   b runs along a portion of channel inlet/outlet  904   ba , with tab  902   af  positioned between side wall  904   b  and line  902   bb.    
   Base portion  902   c  is then bent with respect to side wall  904   c  until the two are at approximately a ninety degree angle. Base portion  902   c  then be bent at approximately ninety degree angles along lines  902   ca ,  902   cb ,  902   cc  and  902   cd  such that an edge of base portion  902   c  runs along portions of channel inlets/outlets  904   ca  and  904   cb . Tabs  902   ce  and  902   cf  may be bent at approximately ninety degree angles with respect to side wall  904   a . Side wall  904   d  may then be bent with respect to side wall  904   c  until the two are at approximately a ninety degree angle. Base portion  902   d  may then be bent at approximately ninety degree angles along lines  902   da  and  902   db  such that an edge of base portion  902   d  runs along a portion of channel inlet/outlet  904   ca , with tab  902   cf  positioned between side wall  904   d  and line  902   db.    
   Side wall  904   c  is then bent with respect to side wall  904   b  until the two are at approximately a ninety degree angle. Tab  902   ce  may then be positioned between side wall  904   b  and line  902   bb  with an edge of base portion  902   b  running along a portion of channel inlet/outlet  904   cb , and tab  902   ae  may be positioned between side wall  904   d  and line  902   db  with an edge of base portion  902   d  running along a portion of channel inlet/outlet  904   aa . In an exemplary embodiment, tab  904   da  may be secured to side wall  904   a  using glue, staples, or other conventional securing means known in the art. In an exemplary embodiment, tab  904   ae  may be secured to tab  902   cf  using glue, staples, or other conventional securing means known in the art. In an exemplary embodiment, tab  904   af  may be secured to tab  904   ce  using glue, staples, or other conventional securing means known in the art. In an exemplary embodiment, base portion  902   a  may be secured to base portion  902   b  using glue, staples, or other conventional securing means known in the art. In an exemplary embodiment, base portion  902   a  may be secured to base portion  902   c  using glue, staples, or other conventional securing means known in the art. In an exemplary embodiment, base portion  902   a  may be secured to base portion  902   d  using glue, staples, or other conventional securing means known in the art. In an exemplary embodiment, base portion  902   c  may be secured to base portion  902   b  using glue, staples, or other conventional securing means known in the art. In an exemplary embodiment, base portion  902   c  may be secured to base portion  902   d  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 ,  9   a ,  9   b ,  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.