Patent Publication Number: US-6668734-B2

Title: Disposable/recyclable pallet and method

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application is a continuation-in-part of co-pending U.S. patent application Ser. No. 09/809,678 filed Mar. 14, 2001 for DISPOSABLE/RECYCLABLE PALLET AND METHOD of Philip J. Lucas et al., which is hereby specifically incorporated by reference for all that is disclosed therein. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to pallets used to support and transport a load of packages, and, in particular, to disposable and/or recyclable pallets and methods for producing the same. 
     BACKGROUND OF THE INVENTION 
     Pallets are typically used to support a load of packages, allowing the load to be lifted and transported by a lift truck such as a forklift. Several layers of packages may be loaded onto a pallet, and the load may then be secured around its circumference using, for example, flexible wrap or shrink-wrap in order to stabilize the load on the pallet. 
     Some pallets have a platform upon which the packages are loaded and a base having channels adapted to receive the “forks” of a forklift. These pallets, hereinafter referred to as “platform-type pallets”, are typically constructed from wood or plastic, and may be re-used multiple times. Disadvantages to using platform-type pallets involve the cost of producing the pallet, space required for and cost of storing the pallets, cost of shipping the pallet and its load to their destination, and cost and inconvenience of shipping the pallet back from its destination so it may be reused. The shipping costs are even more significant for relatively heavier pallets (e.g., wood pallets). Due to weight restrictions, the amount of product that can be shipped with the relatively heavier pallets is reduced. Furthermore, while these pallets are generally reusable, they are subject to breakage (especially wood pallets). 
     A relatively thin and lightweight alternative to a platform-type pallet is known as a “slip sheet” or “slip pallet”. Referring to FIG. 1, a conventional slip pallet  10  may be, for example, a thin sheet of lightweight material such as plastic having one or more extending edges  12 . The slip pallet  10  is loaded with packages  20  and the packages are usually wrapped around the circumference of the load (i.e., around a vertical axis) in order to stabilize the load  22 . A specially adapted lift truck  24  grasps an edge, e.g.  12 , of the slip pallet  10 , pulls the slip pallet  10  onto a platform  26 , and then lifts and transports the load  22  as desired. As the load  22  is lifted and transferred onto the platform  26 , the weight of the load  22  shifts from the leading end  14  to the opposite (trailing) end  16  (as indicated by “L1” and “L2”), possibly damaging packages (e.g.,  20   a ,  20   b ) located on the lowermost layers  18  on these ends  14 ,  16 . The greater the lift angle “A”, the greater the weight “L2” exerted on the packages (e.g.,  20   b ) located on the trailing end  16 , especially those on the lowermost layers  18 . 
     Using either a platform-type pallet or a slip pallet, additional damage may occur to the lowermost layers of packages during shipping due to vibration and jostling of the load. 
     In view of the above, it is an object of the present invention to provide a pallet that essentially functions as a disposable/recyclable platform-type pallet. It is also an object of the present invention to provide a pallet that provides a shock-absorbing effect during transport of the load. It is a further object of the present invention to provide a method for producing such a pallet. 
     SUMMARY OF THE INVENTION 
     A pallet for supporting a load of packages is disclosed. The pallet includes a support structure which may comprise flexible film wrapped around at least one of the layers of the load (e.g., the lowermost layer). The flexible film is wrapped around two axes which are generally perpendicular to one another and preferably located within the same plane such that the flexible film covers at least a majority of the layer(s). The pallet also includes a base which may comprise at least one elongate tubular member having an upper, outer surface positioned adjacent to the bottom surface of the support structure. The elongate tubular member may further comprise at least one opening therethrough which is adapted to receive forks of a forklift. 
     A method for producing the pallet of the present invention is also disclosed. The method includes the initial steps of wrapping at least one of the layers of the load with a flexible film around a first axis, and then wrapping the same layer(s) with a flexible film around a second axis which is generally perpendicular to the first axis and preferably located on the same plane, thereby producing a support structure. The base described above may be assembled by removably attaching a first portion to a second portion, thereby producing a first elongate tubular member having a first opening therethrough, and then removably attaching a third portion to a fourth portion, thereby producing a second elongate tubular member having a second opening therethrough. The support structure may then be placed on the assembled base. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Illustrative and presently preferred embodiments of the invention are illustrated in the drawings in which: 
     FIG. 1 is a side elevation view of a lift truck manipulating a load on a conventional slip pallet; 
     FIG. 2 is an isometric view of a load on the pallet of the present invention; 
     FIG. 3 is an isometric, exploded view of the pallet of FIG. 2 with the load removed; 
     FIG. 4 is a bottom plan view of the pallet of FIG. 2; 
     FIG. 5 is a bottom plan view of another embodiment of the pallet of FIG. 2; 
     FIG. 6 is a front elevation view of a load on the pallet of FIG. 2 being lifted by the forks of a forklift; 
     FIG. 7 is an isometric, exploded view of the pallet of the present invention with another embodiment of the base; 
     FIG. 8 is a front elevation view of an elongate tubular member of the base of FIG. 7; 
     FIG. 9 is a detailed, partially exploded, front elevation view of the elongate tubular member of FIG. 8; 
     FIG. 10 is a front elevation view of a load on the pallet of FIG. 7 with forks of a forklift extending through the base thereof; 
     FIG. 11 is a front elevation view of a stack of disassembled elongate tubular members; 
     FIG. 12 is a front elevation view of another embodiment of the elongate tubular member of FIG. 8; 
     FIG. 13 is a front elevation view of yet another embodiment of the elongate tubular member of FIG. 8; 
     FIG. 14 is a front elevation view of yet another embodiment of the elongate tubular member of FIG. 8; 
     FIG. 15 is a front elevation view of yet another embodiment of the elongate tubular member of FIG. 8; 
     FIG. 16 is a front elevation view of still another embodiment of the elongate tubular member of FIG. 8; and 
     FIG. 17 is an isometric view of another embodiment of the elongate tubular members of FIGS.  7  and  8 . 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     As shown in FIG. 2, the pallet  100  of the present invention is adapted to support a load  50  of packages  52 , allowing the load to be lifted and transported by a conventional lift truck such as a forklift. A typical load  50  is comprised of several layers  54 , including a lowermost layer  54   a . The packages  52  may be, for example, rectangular-shaped cartons as shown in the drawings. However, these packages  52  are merely exemplary, and it is to be understood that the pallet  100  of the present invention may be adapted to support other types of packages. Furthermore, the size of the load  50  shown is also merely exemplary, and the pallet  100  of the present invention may be adapted to support other load configurations. For example, several loads  50  and pallets  100  may be stacked on top of one another, and the lowermost pallet  100  may be adapted to support all of the other loads  50  and pallets  100  thereon. 
     As shown in FIGS. 2-3, the pallet  100  may comprise a base  102  and a support structure  104 . The support structure  104  utilizes at least one of the lowermost layers (e.g.,  54   a ) of the load  50  as a “platform” to support the remaining layers  54 . While the lowermost layer  54   a  will be described relative to the support structure  104 , it is to be understood that two or more layers  54  may be utilized to produce the support structure  104 . 
     With reference to FIG. 3, a layer  54   a  of packages  52  is arranged adjacent to one another in a desired configuration, such as, for example, a square or rectangular configuration (commonly referred to as “palletization”, or arranging packages into a pallet-sized layer). The layer  54   a  of packages  52  may comprise a top surface  60 , a bottom surface  62 , a first side surface  64 , a second side surface  66 , a third side surface  68 , and a fourth side surface  70 . The layer  54   a  of packages  52  is then wrapped in a flexible film  110  in the manner discussed below such that all of the surfaces  60 ,  62 ,  64 ,  66 ,  68 ,  70  (or at least a majority thereof) are covered in flexible film  110 , allowing the wrapped layer  54   a  to function as a “support structure” to support the remaining layers  54  (FIG.  2 ), similarly to the platform of a platform-type pallet. Then, the base  102 , which may be comprised of multiple pieces  106  of lightweight material, is adhered to the flexible film  110  on the bottom surface  62  of the layer  54   a . After loading the remaining layers  54  of packages  52  onto the pallet  100 , the entire load  50  (FIG.  2 ), may be secured around its circumference (i.e., around side surfaces  64 ,  66 ,  68 ,  70  of layer  54   a  and the corresponding side surfaces of the remaining layers  54 ) using, for example, flexible wrap or shrink wrap in order to stabilize the load on the pallet as is well-known in the art. By utilizing one or more layers  54  of the load  50  for the support structure  104 , the entire pallet  100  may be dismantled upon arrival to its destination, and the entire pallet  100  and load  50  may be re-utilized, recycled, and/or disposed of. Specifically, the layer(s)  54  of packages  52  used for the support structure  104  will, of course, be utilized by the end-user along with the rest of the load  50 . The flexible film  110  covering the layer(s)  54  as well as the base  102  may be constructed from disposable/recyclable materials. Thus, upon dismantling the pallet  100 , the flexible film  110  and the base  102  may be disposed of and/or recycled. The term “disposable/recyclable” as used throughout this application is intended to encompass the conventional definitions of both the terms “disposable” and “recyclable”, since an end-user of a disposable/recyclable product usually has the option of whether to dispose of or recycle the product. 
     The flexible film  110  may be, for example, a plastic stretch wrap material manufactured by ADU Stretch Films of Tulsa, Okla. The flexible film  110  may be wrapped around the packages  52  using conventional stretch wrap equipment such as that sold by Mima of Tamarac, Fla. (see “www.itwmima.com”). As shown in FIG. 3, the layer  54   a  of packages is preferably wrapped with flexible film  110  around two axes AA, BB. Specifically, the flexible film  110  may be applied to the top surface  60 , first side surface  64 , bottom surface  62 , and second side surface  66  in a first direction, e.g., R 1  (this direction may be either clockwise or counterclockwise), around axis AA. The film  110  is shifted along the load in direction D 1 , preferably overlapping the previous wrap somewhat, until all of the surfaces  60 ,  62 ,  64 ,  66  (or at least a majority thereof) are covered with flexible film  110 . It may be desirable to cover the surfaces  60 ,  62 ,  64 ,  66  with more than one layer of flexible film  110 , as described in further detail below. The flexible film  110  may then be applied to the top surface  60 , third side surface  68 , bottom surface  62 , and fourth side surface  70  in a second direction, e.g., R 2  (again, this direction may be either clockwise or counterclockwise), around axis BB. The film is shifted along the load in direction D 2 , preferably overlapping the previous wrap somewhat, until all of the surfaces  60 ,  62 ,  68 ,  70  (or at least a majority thereof) are covered with flexible film  110 . Again, it may be desirable to cover the surfaces  60 ,  62 ,  68 ,  70  with more than one layer of flexible film  110 , as described in further detail below. It may also be desirable to leave one or more openings (see FIG. 7) within the flexible film  110  on one or more of the surfaces (in particular, on the bottom surface  62  and one or more of the side surfaces  65 ,  66 ,  68 ,  70 ) to allow for drainage of a leaking package  52 . The axes AA, BB are most preferably located on the same plane (e.g., horizontal plane ABAB), and these axes M, BB may be generally perpendicular to one another as shown in FIG. 3, so that the top surface  60  and bottom surface  62  are covered with twice as much flexible film  110  as the sides  64 ,  66 ,  68 ,  70 . 
     As noted above, the base  102  is adhered to the flexible film  110  on the bottom surface  62  of the layer  54   a . The base  102  must therefore be strong enough to support the entire load  50  (as well as other loads and disposable/recyclable pallets which may be stacked on top of this load as noted above), and is preferably constructed of a lightweight, recyclable/disposable material such as the plastic foam known as “Styrofoam”. By utilizing a resilient material such as plastic foam, the base  102  provides a shock-absorbing effect and is a damper to harmonic oscillations which minimizes damage to the packages  52  due to vibration and jostling of the load  50  during transportation thereof. However, the base  102  may be constructed from other materials such as rubber, plastic, or wood, including materials which have previously been recycled such as prefabricated wood. 
     The base  102  may be adhered to the flexible film  110  on the bottom surface  62  using any conventional adhesive such as two-sided tape. However, by using an injection-molded material such as plastic foam (a.k.a. Styrofoam), the need to use a separate adhesive may be avoided. Specifically, when plastic foam is removed from a mold, it remains tacky for a certain period of time. In a first method, a base  102  constructed from plastic foam may be pressed onto the flexible film  110  on the bottom surface  62  of the packages  52  while the base  102  is still tacky and then allowed to fully cure, thereby securing the base  102  to the flexible film  110 . In another method, a base  102  constructed from plastic foam which has already cured may be utilized. At least one surface on the base  102  (e.g., surface  107  on each of the pieces  106 , FIG. 3) may be heated until that surface  107  is tacky or partially melted. Then, the tacky surface  107  may be pressed to the flexible film  110  on the bottom surface  62  of the packages  52 . When the base  102  cools down, it will be adhered to the flexible film  110 . 
     As shown in FIGS. 2 and 4, the base  102  preferably includes channels  108  for receiving the forks (e.g.,  56 , FIG. 6) of a forklift. The base  102  may be adapted to receive the forks of a forklift from any side  120 ,  122 ,  124 ,  126  thereof as shown, or it may be adapted to receive a forklift from only two of those sides, e.g.,  120 ,  122 , as shown in FIG.  5 . To create the channels  108  shown in FIGS. 2 and 4, an exemplary base  102  may be comprised of multiple pieces  106  as noted above. To create the channels  208  shown in FIG. 5, elongate pieces  206  may be provided which, other than their elongated shape, may be identical to the pieces  106  described herein. Alternatively (not shown), the base  102  may be comprised of a single piece of material as long as channels  108 ,  208  are provided for use by a forklift. For example, the pieces  106 ,  206  shown may be connected by thinner pieces of material within the channels  108 ,  208 . 
     The pieces  106  should have a relatively uniform height “H1” (FIG. 3) which leaves enough clearance “H2” (FIG. 2) under the load  50  to allow the forks (e.g.,  56 , FIG. 6) of a forklift to be easily inserted into the channels  108 . For example, the height of the pieces “H1” may be between approximately 3 and 4 inches. The clearance “H2” would be equal to the height of the pieces “H1” less any settling of the pieces  106  due to the weight of the load  50 , the amount of settling depending partly on the material used for the base  102 . 
     Referring now to FIG. 4, the pieces  106  may have any desired surface dimension, e.g., “W2” by “W3”. While rectangular-shaped pieces  106  are shown in the drawings, it is to be understood that the pieces  106  may have any cross-sectional shape such as, for example, square, circular, or polygonal. Furthermore, the surface dimension of each pieces  106  need not be equal to the surface dimension of any other piece  106 , except as necessary to create adequate channels  108 . The “footprint” of the base is equal to the total surface area, for example “A1”+“A2”+“A3”+“A4”+“A5”+“A6”+“A7”+“A8”+“A9” of the pieces  106 , where the surface area of each piece, e.g., “A1”, is equal to the surface dimensions of each piece multiplied together, e.g., “W2”×“W3”. The desired footprint as compared to the total surface area “W4”×“W5” of the bottom surface  62  depends on the weight of the load  50  as well as the material used for the base  102 , as shown in the example below. 
     The particular characteristics of the flexible film  110  and the wrapping thereof, as well as the base  102 , may vary according to particular characteristics of the load  50 . As an example, a load  50  of packages  52  (which may contain, for example, filled beverage cans) may weigh approximately 2,200 lbs. To provide a sufficiently strong yet cost-efficient pallet  100  in accordance with the present invention, a flexible film  110  such as a plastic stretch wrap having a film gauge of between approximately 0.0075 and 0.0095 inches, and most preferably approximately 0.008 inches, may be utilized. This film  110  may have a pre-stretch of between approximately 100 and 200%, but most preferably closer to 200%. The stretch force setting on the stretch wrap equipment may be between approximately 20 and 50 lbs, and most preferably approximately 25 lbs. It should be noted that the film gauge and the stretch force setting should be carefully chosen with regard to the strength the packages and package contents. Specifically, a higher gauge film requires a higher stretch force setting, and a stretch force setting that is too high may cause damage to the packages  52  (especially cardboard packages). 
     In this example, the overlap noted above may be between approximately 25% and 40%, and most preferably approximately 30%, of the width “W1” (FIG. 3) of the flexible film  110 . It was found that damage known as “corner crush” was minimized with a relatively low overlap (e.g., approximately 25% of “W1” in this example). However, lateral movement of the packages  52  was minimized with a relatively high overlap (e.g., approximately 50% of “W1”). Thus, the overlap may be adjusted to minimize the undesired effects. The total number of complete wraps around each axis AA, BB may be between three and five, i.e., the total number of layers of flexible film  110  in this example may be between six and ten. Should a stronger pallet be desired, and/or a heavier load applied, the total number of layers of flexible film may easily be increased, especially since the cost of the flexible film itself is typically relatively low. 
     To complete the pallet  100  described above, an exemplary base  102  constructed from 40-lb. to 60-lb. grade Styrofoam pieces  106  having a height “H2” of approximately 3 inches may be utilized. A base  102  having these characteristics may withstand a maximum load of approximately 40 lbs/in 2 . The exemplary load of 2,200 lbs. would preferably utilize a base with a footprint (as defined above) of between about 25% to 40%, and most preferably approximately 30%, of the total surface area “W4”×“W 5 ” of the bottom surface  62  of the layer  54   a . While a base having a larger footprint may be used, the larger the footprint, the more difficult it may be to insert the forks (e.g.,  56 , FIG. 6) of a forklift into the channels  108 . It is clear that the base  102  of the present invention uses much less material than conventional pallets. Additionally, it will be appreciated that plastic foam/Styrofoam is a relatively inexpensive material as compared to the materials from which conventional pallets are constructed, e.g., plastic or wood. 
     Referring to FIGS. 2 and 3, after the pallet  100  is created by wrapping one or more layers (e.g.,  54   a ) in flexible film  110  and adhering a base  102  thereto, the remaining layers  54  may be loaded onto the pallet  100 . Then, the entire load  50  may be wrapped around its circumference, i.e., around axis CC (a vertical axis which is generally perpendicular to axes AA and BB, and plane ABAB), with flexible film such as stretch wrap, shrink wrap, or the like in a manner well known in the art in order to laterally secure the load  50 . 
     FIG. 6 shows an exemplary load  50  on the pallet  100  of the present invention being lifted by the forks  56  of a forklift (not shown). When the wrapped load  50  is lifted, the lifting force “L3”, “L4” of the forks  56  on the load  50  in combination with the weight “L5”, “L6” of the outer periphery  210  of the load (e.g., the outer row(s) of packages) may cause the load to arch somewhat (as indicated by “DD”). However, since the support structure  104  of the pallet  100  is securely wrapped in two directions (e.g., around axes AA and BB, FIG.  3 ), and due to the friction between the individual packages (e.g., between packages  130  and  132 ,  132  and  134 ,  134  and  136 ) within the wrapped support structure  104 , the support structure  104  does not allow this arching effect to threaten the stability of the load  50 . 
     With reference to FIGS. 1-6, a method for producing the pallet  100  described above is also disclosed. The method may comprise the first step of wrapping at least one of the multiple layers (e.g., the lowermost layer  54   a ) of the load  50  with a flexible film  110  around a first axis AA or BB. The next step involves wrapping the same layer(s)  54   a  with a flexible film  110  around a second axis BB or AA which is generally perpendicular to the first axis and preferably located on the same plane ABAB. Then, a base  102  is adhered to the flexible film  110 . If a plastic foam such as Styrofoam is utilized for the base  102 , the step of adhering the base  102  to the flexible film  110  may comprise providing plastic foam pieces which are not fully cured, pressing the plastic foam pieces onto the flexible film, and then allowing the plastic foam pieces to fully cure, thereby causing the pieces to adhere to the flexible film  110 . Alternatively, as noted above, a base  102  constructed from plastic foam which has already cured may be utilized. At least one surface on the base  102  (e.g., surface  107  on each of the pieces  106 , FIG. 3) may be heated until that surface  107  is tacky or partially melted. Then, the tacky surface  107  may be pressed to the flexible film  110  on the bottom surface  62  of the packages  52 . When the base  102  cools down, it will be adhered to the flexible film  110 . 
     FIG. 7 illustrates a disposable/recyclable pallet  300  with another embodiment of the base  302 . A support structure  304  is illustrated which may be assembled as described above relative to support structure  104 , FIGS. 2 and 3. As noted above, it may be desirable to leave one or more openings  306  within the flexible film  308  on the support structure  304  (in particular, on the side surfaces  310 ,  312 ,  314 ,  316  and the bottom surface  318  of the support structure  304 ) to allow for drainage of a leaking package or the like. 
     The base  302  may comprise at least one, and most preferably two, elongate tubular member(s)  330 ,  332 . FIG. 7 shows a first elongate tubular member  330  in a disassembled, exploded state and a second elongate tubular member  332  in an assembled state. Each of the elongate tubular members  330 ,  332  may be identical to one another and may comprise an upper, outer surface  334  having a width “WW3” (FIG. 8) which is adapted to be positioned adjacent to the bottom surface  318  of the support structure  304 . As shown in FIGS. 7 and 8, each elongate tubular member  330 ,  332  may further comprise at least one opening  336  therethrough extending along a central longitudinal axis “MM”. As described in further detail below, the openings  336  are adapted to receive the forks (e.g.,  56 , FIG. 10) of a forklift. In a preferred embodiment, each of the elongate tubular members  330 ,  332  is adapted to receive one fork (e.g.,  56 , FIG. 10) of a forklift. 
     As shown in FIG. 7, the support structure  304  may comprise a first end  320  which may correspond to a first side surface  310  and a second end  322  which may correspond to a second side surface  312 . The distance between the first end  320  and the second end  322  is designated in FIG. 7 as “WW1”. This distance corresponds to a surface dimension (e.g., length or width) of the support structure  304 , which may vary depending on the surface dimensions of the load (e.g.,  356 , FIG. 10) to be supported. The length “WW2” of each elongate tubular member  330 ,  332  may be identical to or somewhat less than the distance “WW1” such that each elongate tubular member  330 ,  332  extends substantially from the first end  320  to the second end  322  of the support structure  304  (as it is used herein, “substantially” should be interpreted as being within approximately zero to 4 inches from each end  320 ,  322 ). 
     As shown in FIGS. 7 and 8, each elongate tubular member  330 ,  332  may comprise a first portion  340  removably attached to a second portion  342 . For ease of manufacturing, the first and second portions  340 ,  342  may be substantially identical to one another. As shown in FIG. 8, the first portion  340  may comprise a first elongate, substantially planar panel  344  (which may include the upper, outer surface  334  described above) and a first pair of elongate side panels  346 ,  348  extending therefrom substantially parallel to the central longitudinal axis “MM”. The second portion  342  may comprise a second elongate, substantially planar panel  350  and a second pair of elongate side panels  352 ,  354  extending therefrom substantially parallel to the central longitudinal axis “MM”. To assemble the first and second portions  340 ,  342  into an elongate tubular member  330 ,  332  as shown in FIG. 7, one of the portions  340  or  342  may be inverted and aligned with another portion  342  or  340 , respectively, and then the portions  340 ,  342  may be removably attached to one another as discussed in further detail below. 
     When assembled, the first and second portions  340 ,  342  may form a tubular structure having an eight-sided cross-sectional shape as shown in FIG. 8 having an opening  336  therethrough and a height “HH1” which may be equal to “H1” described above (the height of the base  102 ), or, alternatively, any height which accommodates a fork ( 56 , FIG. 10) of a conventional forklift. The first and second portions  340 ,  342  of each of the elongate tubular members  330 ,  332  may be constructed from a disposable/recyclable (or reusable) material such as, for example, polystyrene, structural foam, expanded polystyrene, polypropylene, or polyethylene. The first and second portions  340 ,  342  may have a thickness “T1”, the value of which may depend on the type of disposable/recyclable material used for the base  302  as well as the weight of the load  356  (FIG. 10) to be supported on the base  302 . For example, to support a given load  356 , a base  302  constructed from polystyrene (“Styrofoam”) may require a greater thickness “T1” (at least at certain portions of the base; see description of FIG. 15 below) than a base  302  constructed from a relatively denser material such as, for example, polypropylene or polyethylene. 
     As shown in FIGS. 8 and 9, the first pair of elongate side panels  346 ,  348  in the first portion  340  may be removably attached to the second pair of elongate side panels  352 ,  354  in the second portion  342 . The removable attachment of the first portion  340  to the second portion  342  may be accomplished in any conventional manner such as, for example, utilizing a tongue-and-groove configuration as shown in FIG.  9 . For example, one of the elongate side panels (e.g.,  346  or  352 ) in each of the first and second portions  340 ,  342 , respectively, may have an extending member or “tongue”  360  that is adapted to be received within a channel or “groove”  362  in the opposite elongate side panel (e.g.,  354  or  348 , respectively). The portions  340 ,  342  may be “snapped” together (i.e., press or interference fit) by aligning the tongues  360  and their respective grooves  362  and pressing the portions  340 ,  342  together. It should be noted that, by utilizing both a tongue  360  and a groove  362  in each of the portions  340 ,  342 , each of the portions  340 ,  342  may be identical to one another (simplifying manufacturing thereof) while also being removably attachable to one another simply by inverting one of the portions  340 ,  342  as described above. While a tongue-and-groove configuration is shown in FIG. 9, it is to be understood that the present invention is not limited to such a configuration, and any means, conventional or otherwise, for removably attaching the first and second portions  340 ,  342  may be utilized in the present invention. 
     FIG. 10 illustrates an exemplary load  356  on a pallet  300  of the present invention. The pallet  300  includes a support structure  304  (which is part of the load  356  as described above relative to support structure  104 , FIGS. 2-3) and a base  302  which is comprised of a pair of elongate tubular members  330 ,  332  in order to accommodate the forks  56  of a conventional forklift (not shown). The tubular configuration of the elongate tubular members  330 ,  332 , as well as the disposable/recyclable material utilized for their construction (e.g., polystyrene, polypropylene, polyethylene, etc.), allows the elongate tubular members  330 ,  332 , to deform slightly under a load  356 . Thus, the height “HH2” of the base  302  under a load  356  will typically be somewhat less than the height “HH1” of an undeformed, unloaded base  302  (FIG.  8 ). As additional forces are applied to the load  356  (due to, for example, jostling of the load during assembly or transportation thereof), the base  302  is able to deform under such forces to provide a shock-absorbing effect which will minimize damage to the load  356 . 
     As an example (with reference to FIGS.  7 - 10 ), in order to support a load  356  of approximately 2,200 lbs. (as well as up to two loads of the same size stacked thereon, for a total of 6,600 lbs.), a base  302  may be comprised of a pair of elongate tubular members  330 ,  332 . Utilizing a support structure  304  having a distance “WW1” (FIG. 7) between a first end  320  and a second end  322  of approximately 39 inches, the length “WW2” of each elongate tubular member  330 ,  332  may be approximately 35 to 39 inches, and most preferably about 36 inches, such that each member  330 ,  332  extends substantially from the first end  320  to the second end  322  of the support structure  304 . Such members  330 ,  332  that are constructed from, for example, structural foam, expanded polystyrene, polypropylene or polyethylene may have a thickness “T1” (FIG. 8) of between about ⅛ to ¼ inch, and most preferably about ¼ inch. Such members  330 ,  332  that are constructed from a relatively lower density material such as conventional polystyrene may require a greater thickness “T1” and/or relatively thicker portions such as, for example, portions  374  (FIG. 15) which may have a thickness “T2” of approximately 2 inches. In order to provide adequate support to the load  356  as well as to easily accommodate the forks  56  (FIG. 10) of a forklift, the width “WW3” (FIG. 8) of the upper, outer surface  334  of each of the members  330 ,  332 , may be between about 5 to 12 inches, and most preferably about 8 inches. Each of the members  330 ,  332  may have an undeformed height “HH1” of between about 2 to 4 inches, and most preferably about 3 inches (again to easily accommodate the forks  56  of a forklift). Such a base  302  having the above characteristics is designed to withstand a load of approximately 40 lbs/in 2 , or a total of approximately 6,600 lbs. 
     With reference to FIGS. 7-10, a method for producing the pallet  300  described above is also disclosed. The method may comprise the initial steps of wrapping at least one of the multiple layers of the load  356  with a flexible film  308  around a first axis, and then wrapping the same layer(s) with a flexible film  308  around a second axis (as described above relative to the support structure  104  shown in FIGS.  2 - 3 ), thereby producing a support structure  304 . Then, the support structure  304  may be placed on a base  302  which may be assembled by removably attaching a first elongate tubular member  330  to a second elongate tubular member  332 . As noted above, each of the elongate tubular members  330 ,  332  may have an opening  336  therethrough extending along a central longitudinal axis “MM” which is adapted to receive a fork  56  of a forklift. While an adhesive may be placed on the base  302  (specifically, on the upper, outer surface  334 , thereof) or on the support structure  304  prior to placing the support structure  304  on the base  302 , applying an adhesive or the like is not a necessary step since the weight of the load  356  will typically maintain the position of the base  302  under the load  356 . Furthermore, because of the tubular configuration of the base  302 , a forklift can lift both the base  302  and the load  356  (including the support structure  304 ), thereby maintaining the position of the base  302  under the load  356 . 
     As shown in FIG. 11, in addition to preferably being identical to one another, the first and second portions  340 ,  342  when detached from one another are preferably nestable and stackable. In particular, upon disassembly of the pallet  300  (FIG.  7 ), the first and second portions  340 ,  342  of each of the elongate tubular members  330 ,  332  may be detached from one another and nestably stacked as shown in FIG. 11 for ease of storage, shipping, and/or disposal or recycling. The fact that an adhesive need not be applied to the elongate tubular members  330 ,  332  as discussed above simplifies and further accommodates the disassembly and recycling of the pallet  300 . 
     FIGS. 12-16 illustrate various possible configurations of an elongate tubular member  330 ,  332 , each preferably having first and second portions  340 ,  342  removably attached to one another. While no particular means for removably attaching the first and second portions  340 ,  342  is shown in FIGS. 12-16, it is to be understood that any means (such as, for example, the tongue-and-groove configuration shown in FIG.  9  and described above), conventional or otherwise, for removably attaching the first and second portions  340 ,  342  may be utilized with the configurations shown in FIGS. 12-16. 
     As shown in FIGS. 12 and 13, the elongate tubular member  330 ,  332  may have a substantially round (FIG. 12) or oval (FIG. 13) cross-sectional shape. As illustrated, the upper, outer surface  334  of the elongate tubular member  330 ,  332  (which is adapted to be positioned adjacent to the bottom surface  318 , FIG. 7, of the support structure  304 , as noted above) need not be substantially planar. However, when a load  356  (including a support structure  304 , FIG. 10) is placed on a round or oval elongate tubular member  330 ,  332 , at least a portion of the upper, outer surface  334  will naturally conform to the planar bottom surface  318  (FIG. 7) of the support structure  304 . 
     As shown in FIGS. 14 and 15, the elongate tubular member  330 ,  332  may have a substantially square cross-sectional shape. As shown in FIG. 15, the outer circumferential surface  370  of the elongate tubular member  330 ,  332  may have a different cross-sectional shape (e.g., square, as shown) than the inner circumferential surface  372 . Such a configuration may be especially desirable for an elongate tubular member  330 ,  332  which is constructed from polystyrene (“Styrofoam”) or the like which may derive a structural benefit from having certain portions (e.g.,  374 ) which are relatively thicker than other portions (e.g.,  376 ) of the member  330 ,  332 . 
     As shown in FIG. 16, the elongate tubular member  330 ,  332  may comprise a first portion  340  having a rounded cross-sectional shape and a second portion  342  having a planar cross-sectional shape, whereby an upper, outer surface  377  is positioned adjacent to the bottom surface  318  of the support structure  304 . Alternatively, as indicated in FIG. 16, this configuration may be inverted such that the first portion  340  may have a planar cross-sectional shape and the second portion  342  may have a rounded cross-sectional shape, whereby an upper, outer surface  378  is positioned adjacent to the bottom surface  318  of the support structure  304 . This embodiment illustrates that the first and second portions  340 ,  342  of the elongate tubular member  330 ,  332  need not be identical. 
     While particular cross-sectional shapes have been illustrated in FIGS. 7-16, it is to be understood that such configurations are merely exemplary, and that elongate tubular members of various cross-sectional shapes not specifically described herein are within the scope of the present invention. However, in order to provide sufficient support for the load  356  (FIG.  10 ), the cross-sectional shape along at least a majority (i.e., greater than 50%) of the length (“WW2”, FIG. 7) of each of the elongate tubular members  330 ,  332  should be a closed, continuous shape (i.e., not including, for example, an open L-shape or U-shape). 
     FIG. 17 illustrates another embodiment of the base  302  comprising at least one, and most preferably two, elongate tubular member(s)  380 ,  382 . Each of the members may be identical, except where noted otherwise, to the elongate tubular members  330 ,  332  described above and have a length “WW4” which may be equal to the length “WW2” (FIG. 7) of the elongate tubular members  330 ,  332  described above. Each of the elongate tubular members  380 ,  382  may further comprise at least one (and most preferably two) opening(s)  384  in the elongate sides  386 ,  388  of the members  380 ,  382  which is/are adapted to receive forks (e.g.,  56 , FIG. 10) of a forklift. An opening  384  is shown in side  388  through a partially cutaway portion of member  380 . With this configuration, a forklift may enter the base  302  from any side  390 ,  392 ,  394 ,  396  thereof, inserting its forks into the openings  384  in a direction substantially parallel to an axis “NN” which is generally perpendicular to the central longitudinal axis “MM”. It is to be understood that this embodiment is not restricted to the elongate tubular members  330 ,  332  shown in FIGS. 7 and 17, and that any elongate tubular member configuration within the scope of the present invention (e.g., any of the configurations shown in FIGS. 12-16 as well as other configurations not specifically shown or described) may include such openings  384 . As noted above, in order to provide sufficient support for the load  356  (FIG.  10 ), the cross-sectional shape along at least a majority of the length (e.g., “WW2”, FIG. 7) of each of the elongate tubular members  380 ,  382  should be a closed, continuous shape. Since the cross-sectional shape of each of the elongate tubular members  380 ,  382  is not continuous and closed at the openings  384 , the openings  384  in each of the sides  386 ,  388  should extend less than 50% along the length “WW4” of each of the elongate tubular members  380 ,  382 . 
     While illustrative and presently preferred embodiments of the invention have been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed, and that the appended claims are intended to be construed to include such variations, except as limited by the prior art.