Abstract:
A paper pallet generally comprises support blocks, a top pad, and a wrap. The support blocks are of a comb configuration, e.g., honeycomb or hexacomb. The top pad is of a corrugated material and is positioned above the support blocks. The wrap is also of a corrugated material and wraps, via direct contact, the top and side surfaces of the top pad as well as wrapping, via direct contact, at least two side surfaces of the support blocks.

Description:
CLAIM TO PRIORITY 
     The present invention claims priority to U.S. Provisional Patent Application No. 60/155,048, filed Sep. 21, 1999, and entitled “Paper Pallet”. The identified provisional patent application is hereby incorporated by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention is related to pallets and, more specifically, pallets constructed of corrugated components that include a corrugated wrap, a corrugated topper and corrugated support blocks. 
     BACKGROUND OF THE INVENTION 
     Paper pallets are gaining in popularity as they provide consumers with an easily recyclable option as compared to the standard wood pallets that have been used for years. However, paper pallets while desirably recyclable often bring other undesirable features. For instance, paper pallets often provide the user with a pallet of reduced strength as compared to a wood pallet of similar size and configuration. The reduced strength limits the load that the pallet may carry and additionally, allows for the damaging of the pallet itself under heavy loads. As such, there is a need in the art for a paper pallet that provides additional strength and stability, as well as easy assembly through the use of corrugated materials, e.g., a corrugated topper, corrugated support blocks, and a corrugated wrap. 
     SUMMARY OF THE INVENTION 
     The needs described above are in large measure met by the paper pallet of the present invention. The paper pallet generally comprises support blocks, a top pad, and a wrap. The support blocks are of a comb configuration, e.g., honeycomb or hexacomb. The top pad is of a corrugated material and is positioned above the support blocks. The wrap is also of a corrugated material and wraps, via direct contact, the top and side surfaces of the top pad as well as wrapping, via direct contact, at least two side surfaces of the support blocks. 
     The wrap may continue to wrap four sides of the six-sided support block so that the wrap is placed in a position intermediate the support block and top pad and, thereby, may be secured to the bottom surface of the top pad. Alternatively, the wrap may wrap to completely encompass the top pad and support blocks, i.e., in a shell configuration, such that the edges of the wrap join at a seam above the top pad. The wrap generally presents both an upper exterior surface and a lower exterior surface of the pallet; no additional platforms or pads are required above or below the wrap itself. The pallet may additionally include a second wrap for the wrapping of a central support block. This second wrap is secured to the bottom surface of the top pad when the second wrap is used. 
     A method for assembling the pallet generally includes the steps of: (1) presenting the wrap in a flat orientation; (2) securing the top pad to a central portion of the wrap; (3) securing one surface of the support blocks to a portion of the wrap proximate each side of the central portion, i.e., to each side of the top pad; (4) wrapping a second surface of each of the secured support blocks with the wrap; and (5) rolling each of the secured blocks to a position proximate the bottom surface of the secured top pad. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 provides a perspective view of a two-way paper pallet of the present invention. 
     FIG. 2 is an inside view of a wrap of the two-way paper pallet of FIG.  1 . 
     FIG. 3 is an inside view of a top pad of the two-way paper pallet of FIG.  1 . 
     FIG. 4 is a perspective view of a honeycomb block of the two-way paper pallet of FIG.  1 . 
     FIG. 5 is an inside view of a runner of the two-way paper pallet of FIG.  1 . 
     FIG. 6 is a perspective view of a four-way paper pallet of the present invention. 
     FIG. 7 is an inside view of a wrap of the four-way paper pallet of FIG.  6 . 
     FIG. 8 is an inside view of a top pad of the four-way paper pallet of FIG.  6 . 
     FIG. 9 is a perspective view of a honeycomb block of the four-way paper pallet of FIG.  6 . 
     FIG. 10 is a perspective view of alternative embodiment of a two-way paper pallet. 
     FIG. 11 is an inside view of a wrap of the two-way paper pallet of FIG.  10 . 
     FIG. 12 is a perspective view of a honeycomb block of the two-way paper pallet of FIG.  10 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     A paper pallet  10  of the present invention may take a two-way configuration, see FIGS. 1-5, or, alternatively, a four-way configuration, see FIGS. 6-9. Each paper pallet  10 , however, incorporates standard elements, i.e., a wrap  20 , a top pad  22  and a plurality of support blocks  24 . 
     Referring to FIGS. 1-5, the two-way configuration of paper pallet  10  preferably includes wrap  20 , top pad  22 , three support blocks  24 , which comprise two side runners  26  and a central runner  28 , and a central runner wrap  30 . 
     Wrap  20 , an inside view of which is depicted in FIG. 2, preferably comprises a sheet of single-wall corrugated having a kraft outer liner and a kraft inner liner separated by a corrugating medium incorporating a C-flute, i.e., 42 flutes per foot, and having a basis weight of 275 lbs./1000 ft 2 . Wrap  20  is preferably of a rectangular configuration with the direction of corrugation along the elongate side of the rectangle. Of course, other types of corrugated, e.g., different basis weights, flute sizes and classifications, etc., may be used without departing from the spirit or scope of the invention. As shown in FIG. 2, the inside of each side of wrap  20  is preferably die-cut in four locations, as indicated by the dashed lines  32 , to define a section-A  34 , a section-B  36 , a section-C  38 , a section-D  40 , and a central section  42 . The die-cuts enable bending of section-A through section-D around side runners  26  (see FIG.  1 ). 
     Wrap  20  may be of any suitable size, however, by way of non-limiting example, the following dimensions have been found to be appropriate: (1) overall sheet—77{fraction (3/16)} by 48 inches; (2) section-A—5⅛ by 48 inches; (3) section-B—3{fraction (15/16)} by 48 inches; (4) section-C—5{fraction (3/16)} by 48 inches; (5) section-D—4{fraction (7/16)} by 48 inches; and (6) central section—39{fraction (13/16)} by 48 inches. 
     Top pad  22 , an inside view of which is depicted in FIG. 3, preferably comprises a sheet of corrugated, e.g. tri-wall corrugated, having a kraft outer liner and a kraft inner liner, wherein the kraft liners are separated by a corrugating medium incorporating a combination ABC-flute. The corrugated preferably has a basis weight of 1100 lbs./1000 ft 2 . The direction of corrugation of top pad  22  may be opposite to the direction of corrugation of wrap  20 , to provide additional strength and stability to paper pallet  10 . Of course other types of corrugated, e.g., double-wall corrugated, single-wall corrugated, different flute sizes and combinations, different basis weights, etc., may be used without departing from the spirit or scope of the invention. Additionally, a plurality of top pads  22  may be used in combination without departing from the spirit or scope of the invention. In cooperation with the dimensions provided above, by way of non-limiting example, the dimensions of 48 by 39⅝ inches have been found to be appropriate for top pad  22 . 
     Support blocks  24 , a perspective view of which is depicted in FIG. 4, are preferably of a paper honeycomb configuration and, more preferably, are HEXACOMB® blocks manufactured by Pactiv. The HEXACOMB® blocks preferably have a top kraft face  44 , a bottom kraft face  45 , and a type-3 core  46  separating the top and bottom faces. In cooperating with the dimensions provided above, by way of non-limiting example, the dimensions of 48 by 5 by 3¾ have been found to be appropriate for each of the three support blocks  24 . 
     Central runner wrap  30 , an inside of view of which is depicted in FIG. 5, preferably comprises a sheet of single-wall corrugated having a kraft outer liner and a kraft inner liner separated by a corrugating medium incorporating a C-flute. The sheet of corrugated preferably has a basis weight of 275 lbs./1000 ft 2 . Central runner wrap  30  is preferably of a rectangular configuration with the direction of corrugation along the elongate side of the rectangle. Of course, other types of corrugated, e.g., different basis weights, flute sizes and combinations, etc., may be used without departing from the spirit or scope of the invention. As shown in FIG. 5, the inside central runner wrap  30  is preferably die-cut in four locations, as indicated by dashed lines  50 , to define a section-E  52 , a section-F  54 , a section-G  56 , a section-H  58 , and a section-I  60 . The die-cuts enable bending of section-E through section-I around central runner  28 . 
     In cooperating with the dimensions provided above, by way of non-limiting example, the following dimensions for central runner wrap  30  have been found to be appropriate: (1) overall size—23⅞ by 48 inches; (2) section-E—5¼ by 48 inches; (3) section-F—4{fraction (3/16)} by 48 inches; (4) section-G—5{fraction (5/16)} by 48 inches; (5) section-H—4 by 48 inches; and (6) section-I—5⅛ by 48 inches. 
     In assembling the two-way configuration of paper pallet  10 , a side runner assembly  62  is created with side runners  26 , wrap  20  and top pad  22 . To make side runner assembly  62 , top kraft face  44  of side runners  26  are each preferably secured by adhesive to one of section-D  40  of wrap  20 . Top pad  22  is preferably secured by adhesive to central section  42  of wrap  20 . Each side runner  26  is then preferably rolled toward central section  42  such that one side of side runner  26  is covered by section-C  38 , bottom kraft face  45  of side runner  26  is covered by section-B  36 , and the second side of side runner  26  is covered by section-A  34 . With respect to each side runner  26 , the outside surface of section-A  34  is now in position immediately below top pad  22 , i.e., top pad  22  and the outside of section-A  34  are substantially parallel, and is preferably secured by adhesive to top pad  22 . Wrapping side runners  26  in this manner, wherein all sides of each side runner  26  are enclosed by wrap  20 , and wrap  20  is secured, at least in part, to both the top and bottom surface of top pad  22 , provides extra strength and stability to the two-way configuration of paper pallet  10  and helps to reduce the possibility that side runners  26  will separate from wrap  20  or that wrap  20  will separate from top pad  22 . 
     Central runner  28  is preferably wrapped in central runner wrap  30  to create a central runner assembly  64 . In achieving this objective, top kraft face  44  of central runner  28  is preferably secured by adhesive to section-G  56  of central runner wrap  30 . Then, section-H  58  of central runner wrap  30  is folded up to cover a first side of central runner  28  and section-I  60  is folded to substantially cover the bottom kraft face central runner  28 , where section-I  60  is preferably secured by adhesive. Section-F  54  of central runner wrap  30  is then folded up to cover a second side of central runner  28  and section-E  52  is folded to lay atop secured section-I  60 . Section-E  52  is preferably secured by adhesive to secured section-I  60 . 
     Central runner assembly  64  is preferably placed central to side runners  26  in side runner assembly  62 , as shown in FIG.  1 . In cooperating with the dimensions provided above, by way of non-limiting example, a space of approximately 12{fraction (7/16)} by 48 inches is provided on either side of central runner assembly  64 , which allows for placement of forks for lifting. 
     Referring to FIGS. 6-9, the four-way configuration of paper pallet preferably includes wrap  20 , top pad  22 , and nine support blocks  24 , which comprise six side runners  70  and three central runners  72 . 
     Wrap  20 , an inside view of which is depicted in FIG. 7, preferably comprises a sheet of single-wall corrugated having a kraft outer liner and a kraft inner liner separated by a corrugating medium incorporating a C-flute. The sheet of corrugated preferably has a basis weight of 275 lbs./1000 ft 2 . Wrap  20  is preferably of a rectangular configuration with the direction of corrugation along the elongate side of the rectangle. Of course, other types of corrugated, e.g., different basis weights, flute sizes and combinations, etc., may be used without departing from the spirit or scope of the invention. As shown in FIG. 7, wrap  20  preferably includes four rectangular cut-outs  74 . Further, the inside of each side of wrap  20  is preferably die-cut along two lines, as indicated by the dashed lines  76 , to define a section-J  78 , a section-K  80  and a central section  82 . The die-cuts enable bending of section-J  78  and section-K  80  around side runners  70  (see FIG.  6 ). 
     Wrap  20  may be of any suitable size, however, by way of non-limiting example, the following dimensions have been found to be appropriate: (1) overall sheet—68⅞ by 44 inches; (2) section-J—15 by 44 inches; (3) section-K—3¾ by 44 inches; (4) central section—3⅜ by 44 inches; and (5) cut-outs—16¼ by 10 inches. 
     Top pad  22 , an inside view of which is depicted in FIG. 8, preferably comprises a sheet of double-wall corrugated having a kraft outer liner and a kraft inner liner, wherein the kraft liners are separated by a corrugating medium incorporating a combination B/C flute. The double wall corrugated preferably has a basis weight of 350 pounds/1000 ft 2 . The direction of corrugation of top pad  22  may be opposite to the direction of corrugation of wrap  20 , to provide additional strength and stability to paper pallet  10 . Of course, other types of corrugated, e.g., single-wall corrugated, tri-wall corrugated, different flute sizes and combinations, different basis weights, etc., may be used without departing from the spirit or scope of the invention. Additionally, a plurality of top pads  22  may be used in combination with each other without departing from the spirit or scope of the invention. In cooperation with the dimensions provided above, by way of non-limiting example, the dimensions of 30 by 44 inches for top pad  22  have been found to be appropriate. 
     Support blocks  24 , a perspective view of which is depicted in FIG. 9, are preferably of a paper honeycomb configuration and, more preferably, are HEXACOMB® blocks manufactured by Pactiv. The HEXACOMB® blocks preferably have a top kraft face  84 , a bottom kraft face  86  and a type-3 core  88  separating the top and bottom faces. In cooperating with the dimensions provided above, by way of non-limiting example, the dimensions of 8 by 5 by 3¾ inches have been found to be appropriate for each of the nine support blocks  24 . 
     In assembling the four-way configuration of paper pallet  10 , top kraft face  84  of three of side runners  70  are preferably secured by adhesive to a first side of central section  82  of wrap  20 , with the side runner&#39;s elongate side proximate die-cut line  76  of section-K  80  and its short side proximate the edge of wrap  20  and/or the edge of cut-out  74 . The three remaining side runners  70  are preferably placed similarly to the opposite side of wrap  20 . Central runners  72  are preferably secured by adhesive to central section  82  of wrap  20  in a manner to be in substantial alignment with but intermediate to side runners  70 . Top pad  22  is then preferably secured by adhesive to bottom face  86  of all support blocks  24 , i.e., side runners  70  and central runners  72 . 
     With top pad  22  secured, section-K  80  of wrap  20  is folded/bent to cover the elongate sides of all of side runners  70 . Next, section-J  78  of wrap  20  is folded/bent to come over top pad  22  whereby section-J  78  of one side of wrap  20  meets section-J  78  of the other side of wrap  20  to create a seam  90  over the top face of top pad  90 . Each of section-J  78  of wrap  20  is preferably secured to top pad  22  by adhesive to complete assembly of paper pallet  10 . The four-way configuration of paper pallet may now raised and lowered by a forklift in the elongate direction of paper pallet  10  via openings  92 , see FIG. 6, or in the shortened direction of paper pallet via openings  94 . 
     Note that in the four-way configuration of paper pallet  10 , because wrap  20  substantially encloses support blocks  24 , i.e., side runners  70  and central runners  72 , provides only a single seam  90  at the top of paper pallet  10 , and because support blocks  24  are secured to both wrap  20  and top pad  22 , extra strength and stability is provided to paper pallet  10 . Further, these features help to reduce the possibility that support blocks  24  will separate from wrap  20  or top pad  22  during lifting. 
     It should be noted that top pad  22  may be eliminated from the two-way configuration or four-way configuration of paper pallet  10  if the load to be supported by paper pallet does not require the additional strength added by top pad  22 . 
     Referring to FIGS. 10-12, an alternative embodiment of the two-way configuration of paper pallet  10  is shown and preferably includes wrap  20  and three support blocks  24 , which comprise two side runners  26  and a central runner  28 . While not depicted, top pad  22  may be incorporated as well. 
     Wrap  20 , an inside view of which is depicted in FIG. 1, preferably comprises a sheet of single-wall corrugated having a kraft outer liner and a kraft inner liner separated by a corrugating medium incorporating a BC-flute and having a basis weight of 350 lbs./1000 ft 2 . Wrap  20  is preferably of a rectangular configuration with the direction of corrugation along the elongate side of the rectangle. Of course, other types of corrugated, e.g., different basis weights, flute sizes and classifications, etc., may be used without departing from the spirit or scope of the invention. As shown in FIG. 11, the inside of each side of wrap  20  is preferably die-cut in two locations, as indicated by the dashed lines  32 , a section-C  38 , a section-D  40 , and a central section  42 . The die-cuts enable bending of section-C through section-D around side runners  26  (see FIG.  10 ). 
     Wrap  20  may be of any suitable size, however, by way of non-limiting example, the following dimensions have been found to be appropriate: (1) overall sheet—57{fraction (13/16)} by 48 inches; (2) section-C—5 by 48 inches; (5) section-D—4{fraction (1/16)} by 48 inches; and (6) central section—39{fraction (11/16)} by 48 inches. 
     Top pad  22 , if used, is preferably similar to top pad  22  configuration of FIG.  3  and preferably comprises a sheet of tri-wall corrugated having a kraft outer liner and a kraft inner liner, wherein the kraft liners are separated by a corrugating medium incorporating a combination ABC-flute. The tri-wall corrugated preferably has a basis weight of 1100 lbs./1000 ft 2 . The direction of corrugation of top pad  22  may be opposite to the direction of corrugation of wrap  20 , to provide additional strength and stability to paper pallet  10 . Of course other types of corrugated, e.g., double-wall corrugated, single-wall corrugated, different flute sizes and combinations, different basis weights, etc., may be used without departing from the spirit or scope of the invention. Additionally, a plurality of top pads  22  may be used in combination without departing from the spirit or scope of the invention. 
     Support blocks  24 , a perspective view of which is depicted in FIG. 12, are preferably of a paper honeycomb configuration and, more preferably, are HEXACOMB® blocks manufactured by Pactiv. The HEXACOMB® blocks preferably have a top kraft face  44 , a bottom kraft face  45 , and a type-3 core  46  separating the top and bottom faces. In cooperating with the dimensions provided above, by way of non-limiting example, the dimensions of 48 by 5 by 3¾ have been found to be appropriate for each of the three support blocks  24 . 
     In assembling the alternative embodiment of the two-way configuration of paper pallet  10 , a side runner assembly  62  is created with side runners  26 , wrap  20 , and top pad  22  (if used). To make side runner assembly  62 , top kraft face  44  of side runners  26  are each preferably secured by adhesive to one of section-C  38  of wrap  20 . Top pad  22 , if used, is preferably secured by adhesive to central section  42  of wrap  20 . Each side runner  26  is then preferably rolled toward central section  42  such that one side of core  46  of side runner  26  is covered by section-D  40 . Bottom kraft face  45  of side runner  46  may additionally be secured to central area  42 , or to the bottom surface of top pad  22 , if top pad  22  is used. 
     Central runner  28  is preferably secured by adhesive to central section  42 , or to top pad  22 , if used. Central runner  28  is preferably placed central to side runners  26  in side runner assembly  62 , as shown in FIG.  10 . In cooperating with the dimensions provided above, by way of non-limiting example, a space of approximately 12½ by 48 inches is provided on either side of central runner  28 , which allows for placement of forks for lifting. 
     The present invention may be embodied in other specific forms without departing from the spirit of the essential attributes thereof; therefore, the illustrated embodiment should be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than the foregoing description to indicate the scope of the invention.