Patent Publication Number: US-2009223422-A1

Title: Pallets rails and methods for making same

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation-in-Part (CIP) application of, and claims the benefit of priority of U.S. patent application Ser. No. 11/625,543, previously filed on Jan. 22, 2007, and entitled “Pallet and Methods for Making Same.” Both this CIP application and the previously filed 11/625,543 application claim the benefit of priority of U.S. Provisional Application No. 60/747,626, filed May 18, 2006. The contents of each of the 11/625,543 and the 60/747,626 applications are hereby incorporated herein by this reference. 
    
    
     TECHNICAL FIELD AND BACKGROUND OF THE INVENTION 
     The invention relates generally to pallets for supporting objects and methods for making same, and more particularly to a pallet rail having arcuate corners to minimize jamming of the pallet rail as it is moved and a pallet rail having an upwardly projecting end wall for aligning the pallet rail along the side of a palletized load. 
     Pallets and pallet components constructed of paper material such as corrugated cardboard are suitable for supporting and transporting many products. Typical cardboard constructions cost less to manufacture and weigh less than wooden pallets. Though typical wood pallets do exhibit higher strength and durability than typical cardboard pallets, wood pallets are typically returned to a shipment supplier for reuse or broken down and discarded and thus their use includes costs that occur after their first use in delivering cargo. 
     Wood pallets occupy space wherever they are collected and are generally formed as one-piece constructions having rails and slats or large-area loading surfaces. They are not conveniently reduced to smaller sizes or easily disassembled for shipment and storage. A wood pallet typically represents the first use of wood, a valuable natural resource, whereas cardboard can be formed from recycled material. 
     Cardboard pallets are in use in industries and developments are occurring to increase their applicability, strength, and convenience. 
     SUMMARY OF THE INVENTION 
     Accordingly, there is a need for improved pallets and pallet rails. Therefore it is an object of the present invention to provide several embodiments of a pallet rail, two or more of which are usable in spaced-apart relation to support respective portions of a rigid load to thereby form a pallet. In a first embodiment, the pallet rail includes an elongate support box, and a plurality of separately formed reinforcing tubes. The support box is formed from a paper blank that is folded along three parallel fold lines to define two laterally spaced-apart side walls, a bottom wall, and a vertically spaced-apart upper support wall for supporting a portion of the rigid load. The reinforcing tubes are positioned within the support box in spaced-apart relation along the length of the box between the bottom wall and upper support wall to reinforce the box and define the distance of the upper support wall above the bottom wall. The two side walls have arcuate corners adjacent the bottom wall to define two opposing longitudinal ends of the support box having curved lower profiles. The paper blank may also be folded along a fourth fold line that is parallel to the three parallel fold lines to define a second bottom wall overlapping the bottom wall. 
     In at least one example according to the first embodiment, the upper support wall has two longitudinal ends each having a central alignment notch for aligning the pallet rail under corresponding alignment notches of the rigid load. The two opposing longitudinal ends of the support box may also have notches formed for receiving and holding a wrapping material for wrapping the pallet rail and rigid load. The paper blank may be formed of corrugated paper, and the reinforcing tubes may be formed of densified paper. 
     In a second embodiment, the pallet rail includes an elongate support box, an adjacent end wall, and a plurality of separately-formed reinforcing tubes. The support box is formed from a paper blank that is folded along three parallel fold lines to define an inner wall, a laterally spaced-apart outer wall, a bottom wall and a vertically spaced-apart upper support wall for supporting one end of the rigid load. The adjacent end wall projects upwardly from the outer wall for engaging one end of the rigid load. The reinforcing tubes are positioned within the support box in spaced-apart relation along the length of the box between the bottom wall and upper support wall to reinforce the box and define the distance of the upper support wall above the bottom wall. There are at least two openings in the inner wall and at least two openings in the outer wall aligned with the at least two openings in the inner wall for receiving the forks of a forklift used to move the pallet. 
     In at least one example according to the second embodiment, an adhesive strip is positioned along the upper support wall for adhering the pallet rail to the rigid load. The pallet rail may also include longitudinally spaced-apart lateral walls extending between the openings in the inner wall and the openings in the outer wall for facing the forks of the forklift used to move the pallet. The paper blank may be formed of corrugated paper, and the reinforcing tubes may be formed of densified paper. 
     In a third embodiment, the pallet rail includes an elongate support box and at least one elongate reinforcing tube. The support box is formed from a paper blank that is folded along three parallel fold lines to define two laterally spaced-apart side walls, a bottom wall, and a vertically spaced-apart upper support wall for supporting a portion of the rigid load. The reinforcing tube is positioned longitudinally within the support box between the bottom wall and upper support wall to reinforce the box. The tube has a diameter that defines the distance of the upper support wall above the bottom wall. 
     In at least one example according to the third embodiment, the pallet rail also includes two separately-formed reinforcing tubes positioned within the support box at opposing longitudinal ends of the elongate reinforcing tube and between the bottom wall and upper support wall to reinforce the box and define the distance of the support wall above the bottom wall. The paper blank may also be folded along a fourth fold line that is parallel to the three parallel fold lines to define a second upper support wall overlapping the upper support wall. 
     It is also an object of the present invention to provide a method of making a pallet rail, two or more of which are usable in spaced-apart relation to support respective portions of a rigid load to thereby form a pallet. In at least one embodiment, the method includes forming a blank into a square tube having a square cross section with four sides each having substantially the same width within the square tube, and positioning a round tube having a diameter substantially the same as the width of the four sides into the square tube to reinforce the square tube. The round tube may be positioned into the square tube by inserting the round tube into a longitudinal end of the square tube, or by hinging at least one of the four sides to open the square tube and passing the round tube laterally into the open square tube. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Some of the objects of the invention have been set forth above. Other objects and advantages of the invention will appear as the invention proceeds when taken in conjunction with the following drawings, in which: 
         FIG. 1  is a perspective view of a pallet according to an embodiment of the invention; 
         FIG. 2  is another perspective view of the pallet of  FIG. 1 ; 
         FIG. 3  is yet another perspective view of the pallet of  FIG. 1 ; 
         FIG. 4  is yet another perspective view of the pallet of  FIG. 1 ; 
         FIG. 5  is partial perspective view of the pallet of  FIG. 1 ; 
         FIG. 6  is a partial cross sectional view of the pallet of  FIG. 1 ; 
         FIG. 7  is a partial perspective view of the pallet of  FIG. 1 ; 
         FIG. 8  is another partial perspective view of the pallet of  FIG. 1 ; 
         FIG. 9  is yet another partial perspective view of the pallet of  FIG. 1 ; 
         FIG. 10  is a partial cross sectional view of the pallet of  FIG. 1 ; 
         FIG. 11  is a partial cross sectional view of a pallet according to another embodiment of the invention; 
         FIG. 11A  is a partial cross sectional view of the pallet of  FIG. 11 , shown in use with a second similar pallet; 
         FIG. 12  is another partial cross sectional view of the pallet of  FIG. 11 ; 
         FIG. 13  is a perspective view of a pallet according to another embodiment of the invention; 
         FIG. 14  is another perspective view of the pallet of  FIG. 13 ; 
         FIG. 15  is a partial cross sectional view of the pallet of  FIG. 14 , taken along lines  15 - 15 ; 
         FIG. 16  is a perspective view of a pallet according to yet another embodiment of the invention; 
         FIG. 17  is a top plan view of a die cut sheet for use in a method of making the pallet of  FIG. 13 ; 
         FIGS. 18-21  are partial perspective views illustrating a method of making the pallet of  FIG. 13 ; 
         FIG. 22  is a perspective view of a pallet according to yet another embodiment of the invention; 
         FIG. 23  is another perspective view of the pallet of  FIG. 22 ; 
         FIG. 24  is a partial cross sectional view of the pallet of  FIG. 23 , taken along lines  24 - 24 ; 
         FIG. 25  is a perspective view of a pallet according to yet another embodiment of the invention; 
         FIG. 26  is a top plan view of a die cut sheet for use in a method of making the pallet of  FIG. 23 ; 
         FIGS. 27-31  are partial perspective views illustrating a method of making the pallet of  FIG. 23 ; 
         FIG. 32  is a perspective view of a pallet according to yet another embodiment of the invention; 
         FIG. 33  is a perspective view of a pallet according to yet another embodiment of the invention; 
         FIG. 34  is a perspective view of a paper blank used to form the pallet rail of  FIG. 37 ; 
         FIG. 35  is a perspective view of the paper blank of  FIG. 34  shown folded along several fold lines in a stage of forming the pallet rail of  FIG. 37 ; 
         FIG. 36  is a perspective view of the paper blank of  FIG. 34  folded to form an elongate support box and ready to receive reinforcing tubes; 
         FIG. 37  is a perspective view a pallet rail, according to a first embodiment of the present invention, having longitudinal ends with curved lower profiles. 
         FIG. 38  is a perspective view of a paper blank used to form the pallet rail of  FIG. 40 ; 
         FIG. 39  is a perspective view of the paper blank of  FIG. 38  shown folded along several fold lines in a stage of forming the pallet rail of  FIG. 40 ; 
         FIG. 40  is a perspective view of a pallet rail, according to a second embodiment of the present invention, having an upwardly projecting end wall for engaging a rigid load; 
         FIG. 41  is a perspective view of a pallet rail, according to a third embodiment of the present invention, having an elongate support box and a longitudinally positioned reinforcing tube therein; and 
         FIG. 42  is a perspective view of another example of a pallet rail, having additional reinforcing tubes within the support box. 
     
    
    
     DETAILED DESCRIPTIONS 
     Referring to the drawings wherein identical reference numerals denote the same elements throughout the various views, a pallet according to an embodiment of the invention is illustrated in  FIGS. 1-4 , and shown generally at reference numeral  10 . The pallet  10  includes a platform  12  with a plurality of circular openings  14  and a leg  22  positioned within each of the openings  14 . The legs  22  are preferably conical and positioned such that the larger diameter end  24  of each leg  22  is connected to the platform  12 , and the smaller diameter end  26  rests on the floor. 
     The platform  12  is formed of double wall corrugated paper having a thickness of 6.5 mm, with nine openings  14  for receiving the legs  22 . Each opening  14  has a diameter of 95 mm. 
     As shown in  FIGS. 3 and 4 , the legs  22  are conical and open at both ends  24 ,  26 , and are tapered at an angle of about 10 degrees. The legs  22  are made of 3-3.5 laps of 380-400 g/sqm paper having a thickness of 630 microns, and have a length of 116 mm. The inner diameter of the large diameter end  24  is 100 mm, and the inner diameter of the small diameter end  26  is 59 mm. The large diameter end  24  has a radius pattern  294 , and the small diameter end  26  has a radius pattern of 177. Each leg  22  preferably weighs 40.7 grams. The pallet  10  is thus conducive to recycling and disposal as it can be made completely of paper. 
     An adhesive, such as ethylene vinyl acetate (EVA) glue is sprayed or spread around the outer rim of the large diameter end  24  of the legs  22 . The legs  22  are then pushed down through the openings  14 . As shown in  FIG. 5 , the platform  12  includes foldable flap sections  16  proximate the openings  14 . The openings  14  are sized such that the flap sections  16  fold downwardly and engage the large diameter end  24  of the legs  22  when the legs  22  are pushed through the openings  14 . The adhesive on the legs  22  adheres to the flap sections  16  of the platform  12 . Alternatively, the adhesive can be put on the flap sections  16  prior to positioning the legs  22  within the openings  14 . 
     As shown in  FIGS. 6 and 7 , each leg  22  has a bull nose  28  formed at the small diameter end  26 . The bull nose  28  is formed by folding a portion of the leg  22  inwardly so that the bull nose  28  extends around the circumference of the inner wall surface of the leg  22 . 
     As shown in  FIGS. 8-10 , the pallet  10  can be nested within another like pallet  10 ′, and vice versa. As shown in  FIGS. 9 and 10 , the bull nose  28  of the first pallet  10  provides a stop for the leg  22 ′ of a second pallet  10 ′ that is being nested within the first pallet  10 . As such, the second pallet  10 ′ is prevented from sliding all the way to the end of the leg  22  of the first pallet  10 , thereby preventing the two pallets  10 ,  10 ′ from getting stuck too tightly together while in storage. This facilitates separation of the two pallets  10 ,  10 ′ when it is desired to next use the pallets  10 ,  10 ′ for material transport. Additional pallets can be nested, such as is illustrated in  FIG. 8 , which shows the nesting of four pallets  10 . 
     In addition to facilitating separation of nested pallets  10 ,  10 ′, the bull nose  28  also adds radial and axial strength to the leg  22 , which compensates for the absence of a bottom panel in the leg  22 , enabling the pallet  10  to withstand heavier loads. Preferably, the pallet  10  can support an evenly distributed mass of about 600 kg. Furthermore, the bull nose  28  provides a smooth surface at the bottom of the leg  22  that facilitates sliding movement of the pallet  10  on a supporting surface such as the ground or floor. 
     A pallet according to another embodiment of the invention is illustrated in  FIGS. 11-12 , and shown generally at reference numeral  100 . The pallet  100  is similar in construction to the previously described pallet  10 , except that each leg  122  of the pallet  100  has two cones  122   a,    122   b.  This construction adds strength to the legs  122  and enables the pallet  100  to withstand heavier loads. 
     Each cone  122   a,    122   b  has flared portions  123   a,    123   b,  respectively, extending outward from the large diameter ends  124   a,    124   b  of the cones  122   a,    122   b.  An adhesive, such as ethylene vinyl acetate (EVA) glue, is sprayed or spread onto the flared portion  123   a  of the outer cone  122   a,  which is then pressed on the lower surface of the platform  112  of the pallet  100 . Adhesive is sprayed at the inner surface of the small diameter end  126   a  of the outer cone  122   a  within the area between the bull nose  128   a  and the sidewall of the cone  122   a.  Adhesive is placed on the flared portion  123   b  of the inner cone  122   b,  and the inner cone  122   b  is positioned on top of the outer cone  122   a,  such that the flared portion  123   b  of the inner cone  122   b  rests on the upper surface of the platform  112 . The small diameter end  126   b  of the inner cone  122   b  contacts the adhesive in the crevice of the bull nose  128   a  of the outer cone  122   a  to adhere the outer cone  122   a  and the inner cone  122   b  together. The inner cone  122   b  does not have a bull nose. 
     As shown in  FIG. 11 , the outer cone  122   a  is sloped at an angle a relative to the vertical axis that is greater than the sloped angle β of the inner cone  122   b.  Preferably, the angle a of the outer cone  122   a  is about ten degrees, and the angle β of the inner cone  122   b  is about eight degrees. This results in an area between the flared portions  123   a,    123   b  of the outer cone  122   a  and inner cone  122   b,  respectively, within which a portion  114  of the platform  112  can be sandwiched. 
     As shown in  FIG. 11A , the leg  122 ′ of a second pallet  100 ′ can be nested within the leg  122  of the pallet  100 , and since the outer cone  122   a ′ of leg  122 ′ of the nesting pallet  100 ′ has a slightly greater angle a than the angle β of the inner cone  122   b  of the receiving pallet  100 , the nesting pallet  100 ′ is not allowed to descend all the way to the very bottom of the leg  122  of the receiving pallet  100 . This prevents the two pallets  100 , 100 ′ from becoming stuck to tightly together and facilitates easy separation of the two pallets  100 ,  100 ′. 
     The pallet  100  can be made of corrugated paper, or other suitable material including moisture resistant paper board. It should be noted that the term “paper” as used throughout this application refers generally to all kinds of paper, including cardboard. 
     A pallet according to another embodiment of the invention is illustrated in  FIGS. 13 and 14 , and shown generally at reference numeral  200 . The pallet  200  includes a platform  212  and three leg members  201 ,  202 ,  203 . 
     The platform  212  has a top side  213  for carrying objects, and an under side  214  opposite the top side  213 . While the platform  212  is preferably rectangular as shown in  FIGS. 13 and 14 , it can be a variety of suitable shapes. Three leg members  201 ,  202 ,  203  are positioned on the under side  214  of the platform in substantially parallel relation to each other. The first leg member  201  is positioned at one end  215  of the platform  212 , and the second leg member  202  is positioned at the opposite end  216  of the platform  212 . The third leg member  203  is positioned intermediate the first and second leg members  201 ,  202  at approximately the center of the platform  212 . The leg members  201 ,  202 ,  203  are substantially parallel with each other. 
     As shown in  FIG. 13 , each of the three leg members  201 ,  202 ,  203  are rectangular, and extend across the width of the platform  212 . As such, the first and second leg members  201 ,  202  are coextensive with the first and second ends  215 ,  216 , respectively, of the platform  212 . 
     The first and second leg members  201 ,  202  each have four walls  201   a - d,    202   a - d,  respectively. The third leg member  203  has a total of five walls  203   a - e.  While the leg members  201 ,  202 ,  203  are preferably rectangular, they can be a variety of shapes, such as conical, triangular or other polygonal shape. In addition, the number of leg members can be varied. 
     The first walls  201   a,    202   a,    203   a  of the leg members  201 ,  202 ,  203  lie flat on the under side  214  of the platform  212 . The second walls  201   b,    202   b,    203   b  extend perpendicularly from the first walls  201   a,    202   a,    203   a  and the third walls  201   c,    202   c,    203   c  extend perpendicularly from the second walls  201   b,    202   b,    203   b.  The fourth walls  201   d,    202   d,    203   d  extend perpendicularly from the third walls  201   c,    202   c,    203   c  back toward the underside  214  of the platform  212 . The fifth wall  203   e  of the third leg member  203  extends perpendicularly from the fourth wall  203   d  and lies parallel to and flat on the first wall  203   a.    
     Each of the leg members  201 ,  202 ,  203  can have a pair of rectangular openings  205  formed in the second and fourth walls  201   b,    201   d,    202   b,    202   d,    203   b,    203   d  of the leg members  201 ,  202 ,  203  and aligned on a horizontal axis that is substantially parallel with the platform  212 . As such, fork-lift forks can be inserted through the openings  205  to engage and lift the pallet  200 . Furthermore, the pallet  200  can be accessed by fork-lift forks from all four sides of the pallet by either inserting the fork-lift forks through the openings  205  in the leg members  201 ,  202 ,  203 , or by insertion of forks in the space  221  between the first and third leg members and the space  223  between second and third leg members. 
     Each of the leg members  201 ,  202 ,  203  can have a plurality of openings  206  formed on the third wall  201   c,    202   c,    203   c  of the leg members  201 ,  202 ,  203 . A support member, such as a conical paper tube  207 , can be positioned within each of the openings  206 . The tubes  207  are positioned within the openings  206  of the leg members  201 ,  202 ,  203  such that the tubes  207  reside in perpendicular relation to the platform  212 , as shown in  FIG. 15 . The tubes  207  provide added strength and stability to the leg members  201 ,  202 ,  203  to enable the pallet  200  to carry heavier loads. 
     The leg members  201 ,  202 ,  203  can be positioned directly on a ground surface and thereby support the platform  212  above the ground surface. Alternatively, the leg members  201 ,  202 ,  203  can be mounted on a substantially flat base member  220 , as shown in  FIG. 16 . The base member  230  can be positioned on a ground surface. 
     A method of making the pallet  200  is illustrated in  FIGS. 17-21 . A blank sheet of material, such as a paper die cut sheet  222 , is provided as shown in  FIG. 17 . Four fold lines  251 ,  252 ,  253 ,  254  are formed at one end  215  of the sheet  222 , and four fold lines  261 ,  262 ,  263 ,  264  are formed at the opposite end  216  of the sheet. Perforated sections  225  are positioned between the first and second fold lines  251 ,  261 ,  252 ,  262 , and between the third fold lines  253 ,  263  and fourth fold lines  254 ,  264  of the sheet  222 . A first plurality of linearly aligned circular openings  206   a  are formed between the first and second ends  215 ,  216  of the sheet  222  and the first fold lines  251 ,  261 , respectively, of the sheet  222 . A second plurality of linearly aligned circular openings  206   b  are formed between the second fold lines  252 ,  262  and the third fold lines  253 ,  263  of the sheet  222 . 
     As shown in  FIG. 18 , the bottom of the support tubes  207  are positioned within circular openings  206   b  on the sheet  222 . The first end of the  215  of the sheet  222  is folded over at ninety degree angles at the first and second fold lines  251 ,  252  such that the top of the support tubes  207  are positioned within the circular openings  206   a,  as shown in  FIG. 19 . The support tubes  207  have a diameter slightly less than the diameter of the openings  206   a,    206   b  such that the tubes  207  are held in place within the openings  206   a,    206   b  by frictional engagement. The sheet  222  is folded at ninety degree angles at the third and fourth fold lines  253 ,  254  to form the rectangular leg member  201  having four walls  201   a - d,  shown in  FIG. 21 . An adhesive can be applied to the sheet  222  to attach wall  201   a  thereto. Alternatively, other suitable attachment means can be employed to hold the leg member  201 , such as staples, nails or other fasteners. The second leg member  202  is made in the same manner as the first leg member  201 , and therefore the process is not described again here. 
     As shown in  FIG. 17 , the sheet  222  has two pairs of notches  226  formed at opposite ends of the sheet  222  between the third fold lines  253 ,  263  and the fourth fold lines  254 ,  264 . When the sides  215 ,  216  of the sheet  222  are folded to form the leg members  201 ,  202  as described above, the notches  226  are positioned at the four corners of the pallet  200  on the fourth walls  201   d,    202   d  of the leg members  201 ,  202 , respectively, as shown in  FIG. 13 . These notches  226  provide an area for receiving and holding a wrapping material, such as polyvinylidene chloride or other plastic wrap that is to be wrapped around the pallet  200  and the objects being carried on the pallet  200 . 
     The third leg member  203  is a separate piece that can be attached at the center for the sheet  222  between the first end  215  and second end  216 . As shown in  FIG. 17 , the sheet  222  has two notches  228  located at opposite sides of the center of the sheet  222 . The third leg member  203  likewise has notches  208  at opposite ends formed in the center of the first and fifth walls  203   a,    203   e.  As such, proper positioning of the third leg member  203  on the sheet  222  is readily obtained by aligning the notches  208  of the leg member  203  with the notches  228  of the sheet  222 , as shown in  FIGS. 13 and 14 . The third leg member  203  can be held in place on the sheet  222  by an adhesive placed on the first wall  203   a  of the leg member  203  or the sheet  222 . Alternatively, other attachment means can be employed such as staples, nails or other fasteners. 
     When the first and second leg members  201 ,  202  have been formed, the perforated sections  225  can be partially detached therefrom to form flaps that can be folded inwardly into the leg members  201 ,  202  to form the openings  205 , shown in  FIG. 13 . The flap sections can be held within the leg members  201 ,  202  by frictional engagement with the first walls  201   a,    202   a  and third walls  201   c,    202   c  of the leg members  201 ,  202 , respectively. 
     A pallet according to yet another embodiment of the invention is illustrated in  FIGS. 22 and 23 , and shown generally at reference numeral  300 . The pallet  300  includes a platform  312  and three leg members  301 ,  302 ,  303 . 
     The platform  312  has a top side  313 , shown in  FIG. 23 , for carrying objects thereon, and an under side  314 , shown in  FIG. 22 , opposite the top side  313 . While the platform  312  is preferably rectangular, it can be a variety of suitable shapes. Three leg members  301 ,  302 ,  303  are positioned on the under side  314  of the platform in substantially parallel relation to each other. The first leg member  301  is positioned proximate one end  315  of the platform  312 , and the second leg member  302  is positioned proximate the opposite end  316  of the platform  312 . The third leg member  303  is positioned intermediate the first and second leg members  301 ,  302  at approximately the center of the platform  312 . The leg members  301 ,  302 ,  303  are substantially parallel with each other. 
     The three leg members  301 ,  302 ,  303  are rectangular, and extend across the width of the platform  312 , as shown in  FIG. 22 . The first and second leg members  301 ,  302  each have four walls  301   a - d,    302   a - d,  respectively. The third leg member  303  has a total of five walls  303   a - e.  While the leg members  301 ,  302 ,  303  are preferably rectangular, they can be a variety of shapes, such as conical, triangular or other polygonal shape. In addition, the number of leg members can be varied. 
     The first walls  301   a,    302   a,    303   a  of the leg members  301 ,  302 ,  303  lie flat on the under side  314  of the platform  312 . The second walls  301   b,    302   b,    303   b  extend perpendicularly from the first walls  301   a,    302   a,    303   a  and the third walls  301   c,    302   c,    303   c  extend perpendicularly from the second walls  301   b,    302   b,    303   b.  The fourth walls  301   d,    302   d,    303   d  extend perpendicularly from the third walls  301   c,    302   c,    303   c  back toward the underside  314  of the platform  312 , as shown in  FIG. 22 . The fifth wall  303   e  of the third leg member  303  extends perpendicularly from the fourth wall  303   d  and lies parallel to and flat on the first wall  303   a.    
     The platform  312  includes wing sections  315   a,    316   a  at opposite ends  315 ,  316 , respectively, as shown in  FIGS. 22 and 23 . As shown in  FIG. 22 , the wing sections  315   a,    316   a  extend outward perpendicularly from. the fourth walls  301   d,    302   d  of the first and second leg members  301 ,  302 , respectively. 
     Each of the leg members  301 ,  302 ,  303  can have a plurality of openings  306  formed on the third wall  301   c,    302   c,    303   c  of the leg members  301 ,  302 ,  303 . A support member, such as conical paper tubes  307 , can be positioned within the openings  306 . The tubes  307  are positioned within the openings  306  of the leg members  301 ,  302 ,  303  such that the tubes  307  reside in perpendicular relation to the platform  312 , as shown in  FIG. 24 . The tubes  307  provide added strength and stability to the leg members  301 ,  302 ,  303  to enable the pallet  300  to carry heavier loads. 
     The leg members  301 ,  302 ,  303  can be positioned directly on a ground surface and thereby support the platform  312  above the ground surface. Alternatively, the leg members  301 ,  302 ,  303  can be mounted on a substantially flat base member  330 , as shown in  FIG. 25 . The base member  330  can be attached to the leg members  301 ,  302 ,  303  using an adhesive or other attachment means, such as staples, nails or other fasteners. The base member  330  can be positioned on a ground surface, and can include openings  336 , which are shaped and sized to receive a pallet jack. 
     A method of making the pallet  300  is illustrated in  FIGS. 26-31 . A blank sheet of material, such as a paper die cut sheet  322 , is provided as shown in  FIG. 26 . Six fold lines  351 ,  352 ,  353 ,  354 ,  355 ,  356  are formed at one end  315  of the sheet  322 , and six fold lines  361 ,  362 ,  363 ,  364 ,  365 ,  366  are formed at the opposite end  316  of the sheet  322 . A first plurality of linearly aligned circular openings  306   a  are formed between the first and second ends  315 ,  316  of the sheet  322  and the first fold lines  351 ,  361 , respectively, of the sheet  322 . A second plurality of linearly aligned circular openings  306   b  are formed between the second fold lines  352 ,  362  and the third fold lines  353 ,  363  of the sheet  322 . 
     As shown in  FIG. 27 , the bottom of the support tubes  307  are positioned within circular openings  306   b  on the sheet  322 . The first end  315  of the sheet  322  is folded over at ninety degree angles at the first and second fold lines  351 ,  352  such that the top of the support tubes  307  are positioned within the circular openings  306   a,  as shown in  FIG. 28 . The support tubes  307  have a diameter slightly less than the diameter of the openings  306   a,    306   b  such that the tubes  307  are held in place within the openings  306   a,    306   b  by frictional engagement. As shown in  FIG. 30 , the sheet  322  is folded at ninety degree angles at the third and fourth fold lines  353 ,  354  to form the rectangular leg member  301  having four walls  301   a - d,  shown in  FIG. 31 . The sheet is folded at ninety degree angles at the fifth and sixth fold lines  355 ,  356  to form a side edge  318  that joins the top side  313  and under side  314  of the platform  322 . 
     As shown in  FIG. 26 , the distance between the end  315  of the platform  322  and the first fold line  351  is greater than the distance between the first and second fold lines  351 ,  352 , second and third fold lines  352 ,  353 , and third and fourth fold lines  353 ,  354 . The relatively greater distance between the end  315  of the platform  322  and the first fold line  351  result in the formation of the wing section  315   a  extending outward from the leg member  301 . 
     An adhesive can be applied to the sheet  322  to attach wall  301   a  thereto, as shown in  FIG. 29 . Alternatively, other suitable attachment means can be employed to hold the leg member  301  to the platform  322 , such as staples, nails or other fasteners. The second leg member  302  is made in the same manner as the first leg member  301 , and therefore the process is not described again here. 
     The third leg member  303  is a separate piece that can be attached at the center for the sheet  322  between the first end  315  and second end  316  of the platform  322 . The third leg member  303  can be held in place on the sheet  322  by an adhesive  340  placed on the first wall  303   a  of the leg member  303  or the sheet  322 . Alternatively, other attachment means can be employed such as staples, nails or other fasteners. 
     Yet another alternative embodiment of the invention is illustrated in  FIG. 32 , and shown generally at reference numeral  400 . The pallet  400  includes a platform  412  and two leg members  401 ,  402 , and is similar to the previously described pallet  200 , but does not have a third leg member between the first and second leg members  401 ,  402 . One advantage of pallet  400  is that it can be made entirely of a single sheet of paper or other suitable material. 
     A pallet according to yet another embodiment of the invention is illustrated in  FIG. 33 , and shown generally at reference numeral  500 . The pallet  500  includes a platform  512 , and two elongate rectangular leg members  501 ,  502 . A plurality of conical leg members  522  are positioned between the two elongate rectangular leg members  501 ,  502 , and are arranged in a line that is parallel with the rectangular leg members  501 ,  502 . Although leg members  522  are conical, the leg members  522  can be other shapes such as tubular or square. 
     A pallet rail  600  according to at least one embodiment of the invention is shown in various stages of assembly in  FIGS. 34-36 , and is shown assembled in  FIG. 37 . Two or more of the assembled pallet rails  600  are usable in spaced-apart relation to support a rigid load and to form a pallet with the load. The assembled pallet rail  600  includes an elongate support box  602  and a plurality of separately-formed reinforcing tubes  640 , which are shown in  FIG. 36  prior to being positioned in the support box  600  to form the reinforced pallet rail shown in  FIG. 37 . 
     To form the support box  602 , a paper blank  604  is folded along three parallel fold lines  606 ,  607  and  608  as shown in  FIGS. 34-35  to define walls of the support box  602 . The support box  602  has two laterally spaced-apart side walls  610  and  612 , a bottom wall  614 , and a vertically spaced-apart upper support wall  616  for supporting a rigid load. In the illustrated embodiment, the paper blank  602  is folded along a fourth fold line  609  that is parallel to the three fold lines  606 - 608  to define a second bottom wall  618  ( FIG. 35 ) overlapping the bottom wall  614  as shown in  FIG. 36 . 
     The first and second bottom walls  614  and  618  may be fixed into their illustrated overlapping relation by an adhesive such as ethylene vinyl acetate (EVA) glue that is sprayed or spread onto either or both of their mutually contacting surfaces. Other adhesives and mechanical connectors such as staples can also be used. By fixing the first and second bottom walls together, the support box  602  is fixed in its assembled state as shown in  FIG. 36 . 
     The upper support wall  616  has multiple openings  620  as shown in  FIG. 36 , having at least arcuate circular portions, for receiving the reinforcing tubes  640  and retaining the reinforcing tubes  640  in a friction-fit engagement within the support box  602  as shown in  FIG. 37 . The reinforcing tubes  640  are positioned within the support box  602  in spaced-apart relation along the length of the support box  602  between the bottom wall  614  and upper support wall  616  to reinforce the support box  602  and to define the distance of the upper support wall  616  above the bottom wall  614 . This construction enables the pallet rail  600  to withstand heavier loads. The reinforcing tubes can be fixed into their illustrated positions by use of an adhesive such as ethylene vinyl acetate (EVA) glue fixing each to the bottom wall  614 . Other adhesives and mechanical connectors such as staples can also be used. 
     Advantageously, the two sidewalls  610  and  612  have arcuate corners  611  ( FIG. 34) and 613  at their longitudinal ends. Thus, the longitudinal ends  603  of the support box  602  have curved lower profiles as shown in  FIG. 37 . This feature minimizes jamming of the pallet rail  600  as it is moved manually or in an automated environment and, for example, when the pallet rail  600  is slid into position under a load. 
     The notches  622  defined by the longitudinal ends  603  of the support box  602  represent another advantageous feature of the inventive pallet rail  600 . The notches  622  are formed in the longitudinal ends of the upper support wall  616 , the bottom wall  614 , and the second bottom wall  618 , for aligning the pallet rail under corresponding alignment notches of a rigid load or other support member used in conjunction with the pallet rail  600  to define a palletized load. For example, the platform  212  of  FIG. 16  has alignment notches  228  by which the pallet rail  600  ( FIG. 37 ) could be aligned with the platform  212  to support the platform in lieu of the leg member  203 . 
     The notches  624  defined by the longitudinal ends  603  of the support box  602  represent another advantageous feature of the inventive pallet rail  600 . The notches  622  are formed in the longitudinal ends of the sidewalls  610  and  612  for receiving and holding a wrapping material when the pallet rail  600  is to be wrapped with a load. This feature is particularly advantageous as a wrapping material is pulled manually from a wide roll and wrapping of a palletized load begins. 
     The paper blank  604  can be made of corrugated paper, or other suitable material including moisture resistant paper board. It should be noted that the term “paper” as used here refers generally to all kinds of paper, including cardboard. The paper blank  604  may be die cut or otherwise prepared from a single planar sample of material or may be assembled from several strips joined, for example along the fold lines illustrated in  FIG. 34 . The reinforcing tubes  640  may be formed of densified paper. For example, the reinforcing tubes  640  may be formed as laminated layered rolls of paper. 
     A pallet rail  700  according to at least one other embodiment of the invention is shown in respective stages of assembly in  FIGS. 38-39 , and is shown assembled in  FIG. 40 . Two or more of the assembled pallet rails  700  are usable in spaced-apart relation to support opposing ends of a rigid load and to form a pallet with the load. The assembled pallet rail  700  includes an elongate support box  702  and a plurality of separately-formed reinforcing tubes  740  as shown in  FIG. 39 . 
     To form the support box  702 , a paper blank  704  is folded along three parallel fold lines  706 ,  707  and  708  as shown in  FIGS. 38-39  to define walls of the support box  702 . The support box  702  is shown partially assembled in  FIG. 39  with the reinforcing tubes  740  positioned therein. The support box  702  as shown in  FIG. 40  has an inner wall  710  and an outer wall  712  laterally spaced-apart from the inner wall  710 , a bottom wall  714 , and a vertically spaced-apart upper support wall  716  for supporting a rigid load. 
     Reinforcing tubes  740  are positioned within the support box  702  in spaced-apart relation along the length of the support box  702  between the bottom wall  714  and upper support wall  716  to reinforce the support box  702  and to define the distance of the upper support wall  716  above the bottom wall  714 . This construction enables the pallet rail  700  to withstand heavier loads. 
     At least two openings  711  in the inner wall  710  and at least two openings  713  in the outer wall  712  are aligned for receiving the forks of a forklift so that a palletized load can be lifted and moved by the forklift. In the illustrated embodiment, the pallet rail  700  includes longitudinally spaced apart lateral walls  720  extending between the openings  713  in the outer wall  712  and the openings  711  in the inner wall  710  for facing the forks of the forklift. 
     Advantageously, as shown in  FIG. 40  the pallet rail  700  includes an end wall  730  adjacent the outer wall  712  and projecting upwardly from the outer wall  712  for engaging one end of a rigid load. This feature advantageously facilitates aligning pallet rails  700  along the sides of a load. In the illustrated embodiment of the pallet rail  700 , the end wall  730  is a portion of the paper blank  704  that extends integrally upward from the outer wall  712  without fold lines between the end wall  730  and outer wall  712 . The end wall  730  guides the pallet rail  700  into alignment with a vertical side of a load as the pallet rail  700  is positioned under the load with the load to be supported by the upper support wall  716 . With two pallet rails  700  positioned at opposing ends of a load, with their inner walls  710  facing inward toward the load and toward each other, and with their outer walls  712  position outward from the load, such that the two pallet rails oppose each other in mirror-image relation, the two pallet rails  700  and the load define a palletized load that can be lifted and moved using a forklift or pallet jack by passing the forks thereof through the openings  711  and  713  of the two pallet rails  700 . 
     In the illustrated embodiment of the pallet rail  700 , an adhesive strip  717  is positioned along the upper support wall  716  to adhere the pallet rail  700  to the bottom of a load to form a palletize load. The adhesive strip  717  includes a double-sided adhesive layer fixed along its bottom side to the upper support wall and releasably retaining a protective layer along its upper side. The protective layer, which may be a strip of waxed paper for example, is removed to expose the adhesive top side of the double sided adhesive layer to prepare the pallet rail  700  for attachment to a load. The palletized load may also be wrapped with a wrapping material, engaging particularly the end walls  730 , to fix the pallet rails into position and to stabilize the load. 
     Furthermore, in the illustrated embodiment, the paper blank  702  of  FIG. 38  includes flaps  718  that are folded along a fourth fold line  709  that is parallel to the three fold lines  706 - 708  to bring the flaps  718  into overlapping relation with the outer wall  712  as the support box  702  is assembled as shown in  FIG. 40 . The flaps  718  may be fixed into their illustrated overlapping relation with the outer wall  712  by an adhesive such as ethylene vinyl acetate (EVA) glue. Other adhesives and mechanical connectors such as staples can also be used. By fixing the  718  and the outer wall  712  together, the support box  702  is fixed in its assembled state as shown in  FIG. 36 . 
     The paper blank  704  can be made of corrugated paper, or other suitable material including moisture resistant paper board. It should be noted that the term “paper” as used here refers generally to all kinds of paper, including cardboard. The paper blank  704  may be die cut or otherwise prepared from a single planar sample of material or may be assembled from several strips joined, for example along the fold lines illustrated in  FIG. 38 . The reinforcing tubes  740  of  FIG. 39  may be formed of densified paper. For example, the reinforcing tubes  740  may be formed as laminated layered rolls of paper. 
     A pallet rail  800  according to at least yet another embodiment of the invention is shown in  FIG. 41 . Two or more of the assembled pallet rails  800  are usable in spaced-apart relation to support opposing ends of a rigid load and to form a pallet with the load. The pallet rail  800  includes an elongate support box  802  and an elongate reinforcing tube  840 . The support box  802  is formed from a paper blank  804  that is folded along three parallel fold lines  806 ,  807  and  808  to define walls of the support box  802 . The support box  802  has two laterally spaced-apart side walls  810  and  812 , a bottom wall  814 , a vertically spaced-apart upper support wall  816  for supporting a rigid load, and opposing longitudinal ends  801  and  803 . 
     The reinforcing tube  840  is positioned longitudinally within the support box  802  along the length of the support box  802  between the bottom wall  814  and upper support wall  816  to reinforce the support box  802  and to define the distance of the upper support wall  816  above the bottom wall  814 . This construction enables the pallet rail  800  to exhibit longitudinal rigidity and to withstand heavier loads, especially when the pallet rail  800  supports a load above an open racking system having spaced beams or when the pallet rail  800  is supported from below at its longitudinal ends  801  and  803 . In the illustrated embodiment, the paper blank  804  is folded along a fourth fold line  809  that is parallel to the three fold lines  806 - 808  to define a second upper support wall  818  overlapping the first upper support wall  816 . 
     The first and second upper support walls  816  and  818  may be fixed into their illustrated overlapping relation by an adhesive such as ethylene vinyl acetate (EVA) glue that is sprayed or spread onto either or both of their mutually contacting surfaces. Other adhesives and mechanical connectors such as staples can also be used. By fixing the first and second upper support walls  816  and  818  together, the support box  802  is fixed in its assembled state as shown in  FIG. 41 . 
     In at least one embodiment of a method of making the pallet rail  800 , the paper blank  804  is formed into the illustrated square tube  802  having a square cross section with four sides  810 ,  812 ,  814  and  816 , each having substantially the same width W as measured internally within the square tube  802 . The round tube  840 , which has a diameter substantially the same as the width of the four sides  810 ,  812 ,  814  and  816 , is positioned into the square tube  802  to reinforce the square tube  802 . 
     In one example of the method, the round tube  840  is positioned into the square tube  802  by inserting the round tube  840  into the longitudinal end  801  or the longitudinal end  803  of the square tube  802 . In another example of the method, the first and second upper support walls  816  and  818  are hinged to open the square tube  802  along the length thereof and the round tube  840  is passed laterally into the square tube  802 . 
     In  FIG. 41 , the round tube  840  has substantially the same length as the square tube  802 . In  FIG. 42 , another embodiment of a pallet rail  900  is shown bearing some similarities to the pallet rail  800  of  FIG. 41 . For example, the support box  902  is formed by folding of a paper blank  904  to defined two laterally spaced-apart side walls  910  and  912 , a bottom wall  914 , and two upper support walls  916  and  918  that are shown in hinged open positions. However, in  FIG. 42 , two separately formed reinforcing tubes  950  and  952  are positioned within the support box  902  at opposing longitudinal ends  939  and  941  of the elongate reinforcing tube  940 . The diameter of the reinforcing tube  940 , and the lengths of the reinforcing tubes  950  and  952 , define the distance between the bottom wall  914  and either of the two upper support walls  916  and  918  once the box is closed by bringing the two upper support walls  916  and  918  into overlapping positions to prepare the pallet rail  900  for use. 
     The paper blank  804  of  FIG. 41  and the paper blank of  904   FIG. 42  can be made of corrugated paper, or other suitable material including moisture resistant paper board. It should be noted that the term “paper” as used here refers generally to all kinds of paper, including cardboard. The paper blanks  804  and  904  may be die cut or otherwise prepared from a single planar sample of material or may be assembled from several strips joined, for example along the folds illustrated in  FIGS. 41 and 42 . The reinforcing tube  840  of  FIG. 41  and reinforcing tubes  940 ,  950  and  952  of  FIG. 42  may be formed of densified paper. For example, the reinforcing tubes  840 ,  940 ,  950  and  952  may be formed as laminated layered rolls of paper. 
     The foregoing has described a pallets and methods for making the same. While specific embodiments have been described, it will be apparent to those skilled in the art that various modifications thereto can be made without departing from the spirit and scope of these descriptions. Accordingly, the foregoing descriptions of the particular embodiments and the best modes for practicing the embodiments are provided for the purpose of illustration only and not for the purpose of limitation.