Patent Description:
Pallets and skids, collectively herein "pallets", in various forms have been an important part of shipping freight since the <NUM>'s. Historically, pallets were constructed of wood. Wooden shipping pallets are relatively costly, heavy and susceptible to damage. Wood continues to dominate the pallet market today. In recent history, lighter plastic pallets and more durable metal pallets have been developed. However, both of these options tend to be costly.

The conditions under which most pallets are used typically results in damage that can render the pallet unusable after a short amount of time. Plastic pallets, when damaged, are typically not repairable. Wood pallets are regularly repaired, but this results in a huge amount of waste wood that is relatively difficult to dispose of. Metal pallets tend to resist damage better but their price point and weight is too high to be usable in typical shipping applications. Industries are almost always looking for ways to save costs. Accordingly, a need exists for lower cost, lightweight pallets. As a result, the past few decades have seen shipping pallets developed from other materials. One such material is corrugated fiberboard. Corrugated fiberboard, in certain aspects, may include a fluted corrugated sheet in combination with one or two flat linerboards formed of paper-based material(s) that may include cellulose derived from wood including other plant-based materials. In certain aspects, the corrugate sheet may include corrugated plastic, or other materials, and combinations of materials, as would be readily recognized by those of ordinary skill in the art upon study of this disclosure. Corrugated fiberboard is a strong renewable material that is one of the most widely recycled materials in the world. Corrugated fiberboard generally has a high tensile strength but its strength under compression is most significant when applied along the longitudinal axis of the flutes. The flutes of the corrugated fiberboard provide a columnar structure along their longitudinal axis that is strong in compression, in certain aspects. Accordingly, it may be advantageous to configure certain components of corrugate pallets with the flutes of the corrugated fiberboard oriented vertically.

To maximize strength and durability, corrugate pallet manufacturers have used manufacturing techniques which cut and laminated corrugated fiberboard with the flutes oriented in the desired orientation and cut the material to form the desired components. The cutting blades typically remove a swath of material equivalent to a width of the cutting blades as the cutting blades cut the laminated corrugated fiberboard into the desired component for the pallet. Use of cutting blades can create a tremendous amount of paper dust that is both a hazard to workers and a disposal problem for the manufacturers. Accordingly, a need exists for efficient methodologies to form corrugate pallets without generating significant amounts of dust.

One solution has been to score or crease corrugate sheets to permit the corrugated fiberboard to be folded into the desired components. However, the folding process complicates and slows the manufacturing process as both sides of the corrugated fiberboard sheets require the application of an adhesive to hold the component in its finished and folded configuration and the folding process of a single corrugated fiberboard sheet is relatively slow and mechanically complex. Further, the integrity of the bond adjacent to the fold may also be compromised, as there is a tendency for the linerboard to separate at the fold and to fail to properly bond. Also, both the creasing and the folding of corrugate sheets can compromise the structure of the flutes in areas adjacent to the score or crease reducing the compressional strength of the resulting laminated corrugate structure. The geometry of a folded corrugated fiberboard sheet can also create alternating high and low ridges on the upper and lower surface of a corrugated stringer that can result in less bonding surface. This reduces the surface area available for the adhesive bonding used in many corrugate pallet designs that can weaken the resulting stringer and its adhesive bond with other pallet elements. Alternatively, fully precutting each corrugated fiberboard sheet into plurality of separate individual corrugate pieces and laminating the individual cut corrugate pieces into the individual components can address these problems but is highly inefficient and cost prohibitive.

Therefore, a need exists for efficient manufacturing of corrugate components for pallets from corrugated fiberboard that does not compromise the strength or durability of the components and is also cost effective.

<CIT>) discloses a pallet for supporting a load during transit and storage comprising: a plurality of spaced, generally parallel runners, each of the runners comprising a plurality of layers of paperboard adhered together in a generally vertical orientation; at least two spaced portals in each of the runners, the respective portals of each of the runners being aligned with one another so that tines of a lift truck can be inserted into the portals in a direction generally perpendicular to the runners for lifting the pallet and the load supported thereon, each of the portals being spaced from a bottom surface of the runner to inhibit the pallet and load from tipping off of the tines when inserted therein, the runners being spaced so that the tines can alternatively be inserted generally parallel to the runners for lifting the pallet and load; and a generally planar deck sheet joined to each of the runners.

<CIT>) discloses a pallet constructed of a laminate, which is formed into stringers and ribs, an inner skin blank, and an outer skin blank. The stringers and ribs are formed from a stringer blank, which is die-cut and sliced into strips. This stringer blank contains body pieces and locking keys, which are used to assemble the stringers and ribs for the pallet. The body pieces are folded along score lines and placed into a rectangular shape, which has one continuous and planar edge and one crenellated edge. The crenellated edge contains grooves which receive the locking keys. The keys are inserted into the grooves until the edges are coplanar with the edges of the body pieces, providing stability and rigidity to the stringers and ribs.

The invention provides a method for simultaneously manufacturing a plurality of stringers for a pallet from sheets of corrugate, comprising:.

The invention also provides a product comprising a plurality of corrugate sheets cut to define a plurality of stringers and bonded in a plurality of layers, characterised in that the stringers are interconnected by a plurality of shear bridges to form a laminated corrugated stringer block.

Products and methods in accordance with the present invention may resolve many of the needs and shortcomings discussed above and may provide additional improvements and advantages that may be recognized by those of ordinary skill in the art upon study of the present disclosure.

Products in accordance with various aspects of the present inventions may be configured as shipping pallets. The shipping pallets may include an upper deck and two or more stringers. The upper deck may include one or more deck boards. In certain configurations, the shipping pallets may also include a lower deck. The upper deck and lower decks may be adhesively bonded to the stringers, may be secured by mechanical fasteners or by notched engagements between the stringers and/or deck boards.

Methods in accordance with aspects of the present inventions may be utilized to form shipping pallets. The methods are for manufacturing stringers for pallets from sheets of corrugate. The methods allow for the simultaneous build-up of a plurality of corrugate stringers while laminating corrugate sheets. The method includes providing a plurality of corrugate sheets sized and/or arranged to be die cut into stringers. The corrugate sheets are each die cut to form a plurality of stringer shape sheets. Each stringer shape sheet has a plurality of stringers defined by cuts from an upper surface of the corrugate sheets through the lower surface of the corrugate sheets. Each stringer on each stringer shape sheet is linked to the adjacent stringer by a plurality of shear bridges. The shear bridges are links of uncut corrugate material between the adjacent stringers. Once die cut, the stringer shape sheets are aligned over one another to superimpose the shape of the plurality of stringers on the adjacent stringer shape sheets. The adjacent sheets are typically bonded to one another with an adhesive to form laminated corrugate stringer blocks. The adhesive may be placed on one or more of the abutting surfaces in the laminate. The bonding step may include the coating at least one of an upper surface and a lower surface of the stringer shape sheets with an adhesive. Once formed, the laminated corrugate stringer block includes a plurality of stringers linked by a plurality of shear bridges. The stringers are released by severing, typically by tearing or cutting, the plurality of shear bridges to release one or more of the stringers from the corrugate block. The severing of the plurality of shear bridges may include applying a force to at least one of the plurality of stringers to break each of the plurality of shear bridges between the stringer and the corrugated stringer block to release a stringer from the laminated corrugate stringer block. The method can further include aligning of the plurality of stringer shape sheets to superimpose the shear bridges on the adjacent corrugate sheets. In this aspect, the shear bridges are die cut in each stringer shape sheet such that, when the stringers are superimposed over one another, each of the shear bridges is superimposed over the shear bridges on the other stringer shape sheet layers in the laminated corrugate stringer block.

All Figures are exemplary and selected for explanation of the basic teachings of the present inventions only. Extensions of the Figures with respect to number, position, relationship and dimensions of the parts to form the preferred implementation will be explained or will be within the skill of the art after the following description has been read and understood. Further, the exact dimensions and dimensional proportions to conform to specific force, weight, strength, and similar requirements for various implementations will likewise be within the skill of the art after the following description has been read and understood.

Where used in the various Figures, the same numerals designate the same or similar elements. Furthermore, when the terms "top," "bottom," "right," "left," "forward," "rear," "first," "second," "inside," "outside," and similar terms are used, the terms should be understood in reference to the orientation of the implementations shown in the drawings and are utilized to facilitate description thereof. Else herein of relative terms such as generally, about, approximately, essentially, may be indicative of engineering, manufacturing, or scientific tolerances such as <NUM>%, ±<NUM>%, ±<NUM>%, ±<NUM>%, or other such tolerances, as would be recognized by those of ordinary skill in the art upon study of this disclosure.

The Figures generally illustrate exemplary implementations of a shipping pallet <NUM> and the corrugate stringers <NUM> used in shipping pallets <NUM> that include aspects manufactured in accordance with the present inventions. The particularly illustrated implementations of the stringers <NUM> have been chosen for ease of explanation and understanding of various aspects of the present inventions. It will be understood that the term shipping pallet shall include other similar products used for shipping cargo such as skids, shipping crates, shipping spacers and the like that may use the corrugate stringers <NUM> or other structurally similar components manufactured in accordance with methods of the present teachings. That said, the illustrated implementations are not meant to limit the scope of coverage but, instead, to assist in understanding the context of the language used in this specification and in the appended claims. Accordingly, the appended claims may encompass variations of stringers <NUM> and similar pallet and packing components that differ from the illustrated implementations.

The present inventions provide methods for the manufacture of shipping pallet <NUM> and components thereof for use in shipping and storage applications. The shipping pallets <NUM> are predominately manufactured from corrugated fiberboard or corrugated plastic, both of which are referred to collectively hereinafter as corrugate. As noted below, these sheets when laminated can include alternative materials in certain layers of the laminate. An exemplary shipping pallet <NUM> is illustrated in <FIG>. Shipping pallet <NUM> may be generally configured to support a load that may consist of various items individually, boxed or otherwise packaged. Shipping pallet <NUM> may be configured to be lifted by forklift and, in various implementations, may be configured to be placed, for example, in a storage rack, cargo hold, storage bay, railroad car, or truck trailer. Shipping pallet <NUM> may be configured as either a <NUM>-way or as a <NUM>-way pallet. Shipping pallet <NUM>, as illustrated, includes an upper deck <NUM> and one or more stringers <NUM> secured to the upper deck <NUM>, and shipping pallet <NUM> is configured to receive and support a load on the upper deck <NUM>. The stringers <NUM> support the upper deck <NUM>. Upper deck <NUM> may be single solid piece of corrugate, laminated corrugate, or may include two or more deck boards, in various implementations. For example, the upper deck <NUM> may include between <NUM> and <NUM> individual deck boards secured to the upper surface of the stringers <NUM>, but upper deck <NUM> may include more deck boards in certain implementations. Upper deck <NUM> may be generally configured to meet certain capacity requirements, to support a specific load, or to support a specific cargo.

Stringers <NUM> are generally elongated support elements having a generally rectangular side profile, in this implementation. Stringers <NUM> may have a generally flat upper surface and lower surface, and the upper and lower surfaces of stringer <NUM> may include shaped cutouts to receive various components of the pallet <NUM>. The stringers <NUM> may provide notches <NUM> for the tines of a forklift or for a pallet jack underneath the upper deck <NUM>. Notches <NUM> are configured to receive the tines of a forklift to enable the lifting pallet <NUM> including materials placed upon upper deck <NUM> and extend from one side of the stringer <NUM> through to the other side, in various implementations. The notches <NUM> of adjacent stringers <NUM> of a pallet <NUM> may be aligned with one another to permit the passage of the tines of a forklift and/or, in certain configurations, a pallet jack through the side of shipping pallet <NUM> to provide more flexible access and utility in shipping pallet <NUM>.

Lower deck <NUM> may also be included in pallet <NUM>, in certain implementations. The two or more stringers <NUM> are generally secured between the upper deck <NUM> and the lower deck <NUM>, as illustrated. The lower deck <NUM> may be, for example, a single solid piece of corrugate or multiple pieces of laminated corrugate. In other implementations, the lower deck <NUM> may be composed of a fiberboard or other material. Lower deck <NUM> may include <NUM> or <NUM> separate boards configured to permit the pallet <NUM> to be used with a pallet jack that, for example, allows a user to manually raise and move a loaded pallet <NUM> around a warehouse. In one implementation, the shipping pallet <NUM> may be manufactured solely or predominantly from recyclable materials, such as, for example, paper, corrugate, fiberboard and other paper products.

In accordance with the present inventions, a plurality of stringers <NUM> are simultaneously formed from corrugate sheets <NUM> laminated together. An exemplary configuration for a corrugate sheet <NUM> is illustrated in <FIG> The corrugate sheets <NUM> used may be, for example,"A","B","C", 'E","F" or"microflute" as well as other flute configurations that may be used in the paper industry, as would be readily recognized by those of ordinary skill in the art upon study of this disclosure. Similarly, the corrugate sheets <NUM> may be single wall, double wall or triple wall as used in the paper industry, as would be readily recognized by those of ordinary skill in the art upon study of this disclosure. It will be appreciated that the fluted medium strength along the load-bearing axis typically increases with flute density. The choice of flute density as well as the materials and choice of adhesive included in the corrugate sheets <NUM> will depend upon the specific design requirements for the stringer <NUM> including the loads to be carried. Typically, each layer of the laminate is selected to have a relatively constant thickness, regardless of whether a layer is composed of a single sheet of corrugate or multiple sheets of corrugate. Stringer <NUM> may include a plurality of corrugated sheets <NUM> and stringer <NUM> may include one or more solid fiberboard layers for added strength. The corrugate sheets <NUM> and, if present, alternative materials are secured together, for example, with an adhesive between the linerboards of the corrugate sheets <NUM>. Specific compositions for the laminate used in stringer <NUM> may be selected based on the particular design requirements for stringer <NUM> including, for example, forces to be supported by stringer <NUM>. Similarly, the orientation of the flutes in the corrugate of stringer <NUM> as well as the geometric configuration of the corrugate may be selected based upon specific design requirements for the stringer <NUM>. In certain implementations, the flutes will be vertically oriented and the flutes of a majority of the layers will be parallel to one another in the vertical orientation.

The stringer <NUM> may be sized to have a length substantially the same as the desired length of the finished shipping pallet <NUM>. This will frequently correspond to the length of the deck board if the upper deck <NUM> is formed from a single board. The width of the stringers <NUM> is generally between about <NUM> inches (<NUM>) and about <NUM> inches (<NUM>). Certain design requirements may require that stringer <NUM> have a greater strength. Stringers <NUM> may be strengthened by increasing in number of layers of corrugate sheet <NUM>, by changing the material of the corrugate sheet <NUM>, through the elimination of notches <NUM>, and/or by the addition of solid fiberboard sheet or sheets of other strong materials into the laminate.

The stringers <NUM> are formed from die cutting individual corrugate sheets <NUM>, laminating them into laminated stringer block <NUM>, and separating the individual stingers <NUM> from the laminated stringer block <NUM>. The process for manufacturing stringers <NUM> in accordance with the present inventions generally includes die cutting a single corrugate sheet <NUM> to define one layer of a laminated stringer block <NUM> that includes a plurality of separate linked stringers <NUM>. When cut, the corrugate sheet <NUM> is transformed into the stringer shape sheet <NUM> which includes the cut outs of individual stringer sections <NUM>. The individual stringer sections remain interconnected by shear bridges <NUM> to hold together as the stringer shape sheet <NUM>. Each stringer section <NUM> will form a layer of a distinct stringer <NUM> after lamination. The shear bridges <NUM> are illustrated in <FIG> for exemplary purposes. The shear bridges <NUM> connect each stringer section <NUM>, before lamination, and stringer <NUM>, after lamination, at multiple points to the adjacent stringer section <NUM> or stringer <NUM>, in various implementations. The shear bridges <NUM> are generally configured to retain the die cut plurality of stringer sections <NUM> in position in a corrugate shape sheet <NUM> as it is processed by individuals and/or machinery during manufacture. This allows multiple stringers <NUM> to be simultaneously laminated in a laminated stringer block <NUM>. A finished laminated stringer block <NUM> comprising a plurality of stringers <NUM> interconnected by the shear bridges <NUM>. The thickness of the laminated stringer block <NUM> corresponds to the desired width of the resulting stringers <NUM> after they are removed from the laminated stringer block <NUM>. The thickness will generally correlate with strength when using the same materials.

The corrugate sheets <NUM> are selected so that the size and strength of the corrugate sheet <NUM>, when laminated, will generate the required strength and, if desired, help minimize the weight of the resulting stringers <NUM>. The corrugate sheets <NUM> may be new or previously used. In certain implementations, the corrugate sheets <NUM> may be derived from Old Cardboard Containers (OCC) that may be readily available from recycling companies. OCC may provide an even more environmentally friendly alternative to new corrugate materials. Repurposing the used material, OCC, as opposed to immediately placing the OCC into the recycle chain may save a significant amount of resources that would otherwise be dedicated to the transportation, recycling and redistribution of the recycled corrugate material derived from the OCC. Thus, the use of OCC in the manufacture of stringers <NUM> generally reduces the environmental footprint of the resulting shipping products. Further, the relatively low cost using OCC as a source for corrugate sheets <NUM>, as opposed to newly manufactured corrugate, may reduce the cost of producing the shipping pallets <NUM>. In one implementation, the efficient integration of multiple corrugate sheets <NUM> may be used in a single layer of the laminate. This permits the use of corrugate sheets <NUM> shorter than the overall length of the stringer <NUM>, which increases the variety of OCC sheet sizes that can be utilized with the present process. This can be particularly important because the sizes of sheets of OCC as corrugate sheet <NUM> may vary in size, which is distinct from manufacturing with new corrugate sheets <NUM> that are typically provided in the desired length and width. New corrugate sheets <NUM> may be sized during its original manufacture to a desired width and length to prevent/reduce waste. This can improve the efficiency of manufacturing, as each corrugate sheet <NUM> may be the same size. However, the reduced cost of OCC as corrugate sheet <NUM> may offset manufacturing efficiencies when using new corrugate sheets <NUM>. In certain implementations, the present disclosure provides a process where OCC may be efficiently integrated into the manufacturing process of laminated stringer <NUM> as the source for as corrugate sheets <NUM>. Further, various manufacturing processes disclosed herein may be used to efficiently to allow a single oversized corrugate sheet <NUM> whether from new corrugate or OCC, to be used in each layer of the laminated stringer block <NUM>. The use of single corrugate sheets <NUM> may increase the strength by eliminating the breaks <NUM> generated when using multiple sheets of corrugate in a layer of laminated stringer block <NUM>. In other implementations, new corrugated sheets <NUM>, fiberboard or plastic, may also or alternatively be used for one or more layers of the laminated stringer block <NUM>.

In certain implementations, the corrugate sheets <NUM> may be cut from their upper surface through to their lower surface to transforms the corrugate sheets <NUM> into corrugate shape sheets <NUM> that include multiple cut out stringer sections <NUM>. As a layer of an individual stringer <NUM> may include multiple stringer sections <NUM>, the stringer sections <NUM> will have a shape corresponding to only a portion of the side profile of the resulting stringer <NUM>. A second and, in some cases, a third stringer section <NUM> would complete remainder of the shape of the stringer's <NUM> side profile in that layer of stringer <NUM>. In stringer sections <NUM> representing the entire length of the stringer <NUM>, the stringer section <NUM> will have a shape that corresponds to the entire length of the side profile of the resulting stringer <NUM>. The process of die cutting may utilize rotary die cutting, flatbed die cutting or other may use other variations of die cutting, as would be readily recognized by those of ordinary skill in the art upon study of the present disclosure. Die cutting may reduce, if not eliminate, dust generated when using a saw to cut corrugate sheets <NUM>, a laminated stringer block <NUM>, or an uncut block of laminated corrugate.

The corrugate sheets <NUM> are die cut to form a stringer shape sheet <NUM>. The stringer shape sheet <NUM> has the shape of a plurality of stringer sections <NUM> cut through it. The stringer sections <NUM> will be superimposed with and bonded to adjacent stringers sections <NUM> of other stringer shape sheets <NUM> in the number of layers required or desired for the final application of stringer <NUM>. Each of the plurality of stringer layers <NUM> on each stringer shape sheet <NUM> is linked to adjacent stringer sections <NUM> by a plurality of shear bridges <NUM>. The corrugate sheets <NUM> may be cut to orient the flutes of the corrugate vertically in the cutout stringer shape such that the flutes will extend from a lower surface to an upper surface of the stringer <NUM> when the corrugate sheets <NUM> are laminated. This configuration may maximize the strength of the corrugate laminate in the vertical axis to maximize the ability of a shipping pallet <NUM> having a stringer <NUM> to support a load. A single corrugate sheet <NUM> may be sized in length and width to form the die cut stringers shape sheets <NUM> without generating any waste cuttings from the ends or sides of the corrugate sheet <NUM>.

Alternatively, the die cutter may be configured to cut oversized corrugate sheets <NUM> to the proper length and width to form the stringer shape sheets <NUM>. Such oversized corrugate sheets <NUM> would result in waste trimmings that may be recycled. Similarly, when a single layer of laminate has multiple stringer shape sheets <NUM> integrated into the layer, the combined length and width of each corrugate sheet <NUM> used in that layer may be selected or cut such that their combined sized and shape form the stringer shape sheets <NUM> without generating any waste cuttings from their ends or sides. Again alternatively, the die cutter may be configured to cut multiple oversized corrugate sheets <NUM> to the proper length and/or width to form a single stringer shape sheet <NUM>. Such oversized sheets would result in waste trimmings that would typically be recycled. [<NUM>] As discussed above, the die cutting of the corrugate sheets <NUM> cuts the outline of the shape of each stringer <NUM> through the corrugated sheet <NUM> as stringer sections <NUM>. This cutting also defines and leaves the plurality of shear bridges <NUM> between the adjacent stringer sections <NUM> on each individual stringer shape sheet <NUM>. This also leaves the adjacent stringers <NUM> connected to one another after lamination and allows for efficient processing during the laminating or"build-up" steps that laminate the adjacent stringer sections <NUM> into stringers <NUM>. There may be at least <NUM> or more shear bridges <NUM> between adjacent stringer sections <NUM>, in various implementations. As illustrated, the shear bridges <NUM> are uncut links of material left in each corrugate sheet <NUM> between the adjacent stringers <NUM>. The shear bridges <NUM> are designed to permit the separation of a substantially finished stringer <NUM> from adjacent stringers <NUM> in the laminated stringer block <NUM> after the adhesive <NUM> has sufficiently cured. The shear bridges <NUM> may be broken by the application of a mechanical force to the laminated stringer block <NUM> thereby releasing the adjacent stringers <NUM> from one another, in certain implementations.

The shear bridges <NUM> are generally configured to permit the stringer <NUM> to be removed from the laminated stringer block <NUM> by the application of a severing force or cutting to the shear bridges <NUM>, in certain implementations. The configuration of the shear bridges <NUM> may vary depending upon the nature and qualities of the materials used. The shear bridges <NUM> may be uncut on either the upper or lower surface of the corrugate sheet <NUM> or the shear bridges <NUM> may be uncut on only an upper or lower surface. That is, one of the upper surface or the lower surface may be cut across or partially across the width of the shear bridge <NUM> while leaving the other surface uncut and intact. Such a configuration could reduce the overall strength of the shear bridge <NUM> to facilitate a clean tear and could reduce any residual artifact <NUM> left after the severing of the stringer <NUM>. Shear bridge <NUM> may have a width between about <NUM> inches (<NUM>) and about <NUM> inches (<NUM>) along the axis of the cut from the die cutter, in various implementations. In implementations where a B or C flute corrugate is used, the width of the shear bridges <NUM> may be about <NUM> inches (<NUM>) wide, which may allow for the efficient severing of the stringer <NUM>. Variations in the materials, such as the used of different grades of corrugate, utilizing a plastic corrugate, or integrating one or more fiberboard layers into the laminate, may allow or necessitate the use of a positioning, width and/or number of shear bridges <NUM>, as will be readily recognized by those of ordinary skill in the art upon study of the present disclosure.

The number and positioning of the shear bridges <NUM> is selected based on the composition of the corrugate sheets <NUM> and, when used, other materials in the laminate. The particular configuration typically seeks to adequately maintain the link between the stringers <NUM> during lamination and to retain the stringers <NUM> on the corrugated stringer block <NUM> until it is desired to sever the stringers <NUM> from the corrugated stringer block <NUM>, in various implementations. The number and positioning of the shear bridges <NUM>, in combination with their width may be selected to at least retain the overall shape and integrity of stringer shape sheet <NUM> as stringer shape sheet <NUM> is subjected to the various mechanical forces as stringer shape sheet <NUM> is passed through the manual and/or automated steps in the assembly of laminated corrugate block <NUM> and to retain the stringers <NUM> on the laminated stringer block <NUM> until it is desired in the process to remove the stringer <NUM> from the laminated stringer block <NUM>. In their general design, the shear bridges <NUM> must retain the stringers <NUM> in relative position with respect to one another in the stringer shape sheet <NUM> as stringer shape sheet <NUM> is cut, transported to a gluer, as a layer of glue is applied by the gluer, and as the stringer shape sheet <NUM> is moved toward and positioned relative to other the stringer shape sheets <NUM> and then laminated into the laminated stringer block <NUM>. Once laminated, shear bridges <NUM> must hold the stringer shape block <NUM> together until the manufacturer desires to separate the individual stringers <NUM> from the stringer block <NUM>.

In certain implementations, the sizing of the shear bridges <NUM> is minimized for any given application to reduce the force required to break the shear bridges <NUM> and separate the adjacent stringers <NUM> and/or minimize residual artifact <NUM> left by the broken shear bridge <NUM> on the upper surface of the stringer <NUM>. The size of the residual artifact <NUM> may be minimized by reducing its size and/or physical profile. Further, the positioning of the shear bridges <NUM> along the stringers <NUM> may be selected to minimize any interference of the residual artifact <NUM> on the upper and lower surfaces of the stringer <NUM> with the adhesive bonding of the upper and lower deck boards with the stringer <NUM>, respectively, or the other components of the pallet <NUM>. That is in certain implementations, the positioning of the shear bridges <NUM> may be selected so that the residual artifact <NUM> is positioned between the deck boards on pallets <NUM> that include multiple separated deck boards. Where the residual artifacts <NUM> are positioned in a location to be bonded, the additional manufacturing step of cutting or abrading the residual artifact <NUM> off of the stringer <NUM> may be integrated into its manufacture. Again, variations in the materials, such as the used of different grades of corrugate, utilizing a plastic corrugate or integrating one or more fiberboard layers into the laminate, may allow or necessitate the use of an alternative width, positioning and/or number of shear bridges <NUM> in various implementations.

A layer of adhesive <NUM>, illustrated in <FIG>, <FIG>, is typically applied to a surface of the stringer shape sheets <NUM>. The adhesive <NUM> may be selected in accordance with the materials being glued to have the strength and characteristics necessary for the end use of the stringer <NUM>, as will be readily recognized by those of ordinary skill in the art upon study of the present disclosure. The adhesive <NUM> may be applied to an upper surface as the stringer shape sheets <NUM> are processed, typically as stringer shape sheets <NUM> lay flat on a surface or on a conveyor. With certain manufacturing methodologies, the adhesive <NUM> may alternatively be placed on a lower surface of the corrugate sheet <NUM>. In various implementations, the adhesive <NUM> is applied over the entire surface that will form the stringers <NUM>. In certain implementations. A surface of stringer shape sheet <NUM> may have adhesive <NUM> applied over a portion of the surface in certain applications and/or for cost savings. Adhesive costs may represent a significant cost in the production of laminated corrugate products and minimizing these costs may be significantly beneficial.

For example, to begin forming the laminate stringer block <NUM>, a second stringer shape sheet <NUM> is superimposed over a stringer shape sheet <NUM> aligning the cut stringer sections <NUM> in each of the two stringer shape sheets <NUM>. The adhesive <NUM> positioned between the two corrugate sheets <NUM> is used to bond the two stringer shape sheets <NUM> together. In some implementations, the shear bridges <NUM> on adjacent stringer shape sheets <NUM> are in the same position and the die cut edges are aligned with one another when the stringer sections <NUM> are superimposed. In other implementations, the shear bridges <NUM> on each stringer shape sheets <NUM> may not correspond to the positioning of the shear bridges <NUM> on the adjacent corrugate sheets <NUM>. Additional stringer shape sheets <NUM> are aligned over and bonded to the laminated stringer block <NUM> until the height of the block equal to or slightly higher than the desired width of the stringer <NUM>, in various implementations. With adhesive <NUM> is of certain adhesive types, the laminated stringer block <NUM> may be placed under compression to assure optimal contact between the layers of the laminate as the adhesive <NUM> cures.

Once adhesives <NUM> have adequately cured or other adequately set, the individual stringers <NUM> may be removed from the laminated stringer block <NUM>. The stringers <NUM> are removed by applying a force to sever the shear bridges <NUM>. The force, for example, may be a shear force to break the shear bridges <NUM> or may be applied by a cutting blade that cuts the shear bridges <NUM>. That is, the severing of shear bridges <NUM> may be through cutting or tearing in variations of the present inventions. In certain automated, semi-automated and manual systems, this force may be a vertical sheer force applied to the bottom or top of a stringer <NUM> to be removed while the laminated stringer block <NUM> is secured in a set position. In certain implementations, the force may be from the impact of a machine component or an impact from the hand of an individual. After removal from the laminated stringer block <NUM>, stringer <NUM> may be used as is or may be further processed to remove the residual artifact <NUM> left by the broken shear bridge <NUM>. Once severed, the shear bridges <NUM> may leave a shear bridge artifact <NUM> where the shear bridge <NUM> was severed. In certain methods and configurations, this shear bridge artifact <NUM> may be left on the resulting stringer <NUM>. In other methods or configurations, this shear bridge artifact <NUM> may be mechanically removed as discussed above.

Turning now to the Figures, aspects of the present invention may include forming a shipping pallet <NUM>, as shown in <FIG>, including stringers <NUM>, as shown in more detail in <FIG>, <FIG> and <FIG>. The shipping pallet <NUM> of <FIG> includes a solid upper deck <NUM>, three stringers <NUM> and a solid lower deck <NUM>. The stringers <NUM> include notches <NUM> that are aligned with one another. The upper deck <NUM> is shown as a single solid piece of laminated corrugate for exemplary purposes. Similarly, the lower deck <NUM> is shown as a single solid piece of laminated corrugate for exemplary purposes. The upper deck <NUM> and the lower deck <NUM> are illustrated as secured to the stringers <NUM> with an adhesive <NUM>. The adhesive <NUM> being positioned between the lower surface of the deck boards and the upper surface of the stringer <NUM> to secure the upper deck <NUM> to the stringers <NUM>. The adhesive <NUM> may also be positioned between the upper surface of the lower deck boards and the lower surface of the stringer <NUM> to secure the lower deck <NUM> to the stringers <NUM>.

<FIG>, <FIG> and <FIG> illustrates the details of an exemplary stringer <NUM>. The stringer <NUM>, as illustrated, was formed by laminating nine layers of stringer shape sheets <NUM> in the build-up for exemplary purposes. Accordingly, the stringer <NUM> includes nine laminated stringer sections <NUM>. The nine illustrated layers include the I<st>, <NUM><rc>^, <NUM>^, 7th, and 9thlayers which are each formed from a single continuous corrugate sheet <NUM> cut into a single stringer shape sheet <NUM>. The <NUM><n>^, <NUM>^, 6th, and 8thlayers are each formed from two stringer sections <NUM> from two separate corrugate sheets <NUM> cut into a two stringer shape sheets <NUM> each aligned in a single layer during at least the lamination process. This may leave a break <NUM> between the adjacent parallel edges <NUM> of the corrugate sheets <NUM> positioned proximate to one another. The edges <NUM> are contiguous or nearly contiguous with one another from the upper surface of the stringer to the lower surface of the stringer <NUM>, in various implementations. Further, the edges <NUM> and resultant breaks <NUM> may be configured to be staggered along the length of the stringer <NUM> to maximize its strength of the stringer <NUM> such that the breaks <NUM> do not significantly weaken the structural integrity or may minimize the weakening caused by having the breaks <NUM>. Further in stringers <NUM> with notches <NUM>, the breaks <NUM> may be positioned not to be coincident with the notches <NUM> of stringers <NUM> along their length as can be seen by comparison of the exemplary breaks <NUM> in the Figures relative to the notches <NUM> along the length of stringer <NUM> to enhance their strength and durability.

The general steps of exemplary manufacturing method <NUM> and intermediates structures are illustrated in <FIG> and in the exemplary process flow diagram of <FIG>. Method <NUM> is entered at step <NUM>. As illustrated in <FIG>, step <NUM> includes providing a first corrugate sheet <NUM>, as shown in <FIG>.

The various successive steps in <FIG> are as follows:.

At step <NUM>, the corrugate sheet <NUM> is die cut to form a stringer shape sheet <NUM>. The stringer shape sheet <NUM> includes a plurality of stringer sections <NUM> linked by a plurality of shear bridges <NUM>. For purposes of explanations, the stringer shape sheet <NUM> cut from the corrugate sheet <NUM> of <FIG> is shown to utilize only about half the corrugate sheet <NUM> in <FIG>and <FIG> The illustrated stringer shape sheet <NUM> of <FIG> defines four stringer sections <NUM>. Each stringer section <NUM> on a single stringer shape sheet <NUM> will form a layer of a separate stringer <NUM>. As particularly illustrated, adjacent stringer sections <NUM> are linked to one another by six shear bridges <NUM>. As discussed above, the shear bridges <NUM> are sized, positioned and to maintain the stringers <NUM> in the correct relative positions to the stringers <NUM> in the other stringer shapes sheets <NUM> that are laminated together into a laminated stringer block <NUM> as illustrated in <FIG>.

At step <NUM>, a subsequent corrugate sheet <NUM> is provided. At step <NUM>, the subsequent corrugate sheet <NUM> is die cut into a subsequent stringer shape sheet <NUM> having a plurality of stringer sections <NUM> linked by a plurality of shear bridges <NUM>. At step <NUM>, the subsequent stringer shape sheet <NUM> is positioned over and aligned with the first corrugate shape sheet <NUM> to superimpose the plurality of stringer sections <NUM> of the stringer shape sheets <NUM> on top of one another.

At step <NUM>, the first stringer shape sheet <NUM> and the second stringer shape sheet <NUM> are bonded to one another while aligned over one another. An adhesive <NUM> compatible with the materials and having the desired bonding strength is used to bond the stringer shape sheets <NUM> to one another. In step <NUM>, at least a portion of a surface of one of the stringer shape sheets <NUM> is coated with an adhesive. The adhesive <NUM>, shown in <FIG> and <FIG>, is typically placed on an upper surface of the stringer shape sheet <NUM> to enable it to be mechanically conveyed without depositing adhesive <NUM> on machinery. When using manual manufacturing or robotic arms the surface of the stringer shape sheet <NUM> coated with adhesive <NUM> can vary. [<NUM>] At step <NUM>, the prior steps starting at step <NUM> are repeated as the laminating or "build-up" process until the thickness of the laminated stringer block <NUM> reaches the desired thickness for the stringers <NUM>. This completes the formation of the laminated stringer block <NUM>. The laminated stringer block <NUM> may optionally also be placed under compression until the adhesive <NUM> has adequately secured the laminated layers of stringer shape sheets <NUM>. This compression can improve the strength of the bonding of the layers. Steps <NUM>, <NUM>, <NUM>, <NUM>, <NUM> are repeated at step <NUM> to form the laminated stringer block <NUM>.

At step <NUM>, stringer <NUM> may be released from the laminated stringer block <NUM> by applying a force to an upper surface of stringer <NUM> to break the plurality of shear bridges <NUM> connecting it to the laminated stringer block <NUM> as shown in <FIG>. Exemplary method <NUM> terminates at step <NUM>. Although method <NUM> is discussed as a series of steps, those skilled in the art may recognize variations of method <NUM> including, for example, the order of the steps or multiple steps that can be combined into a single step without departing from the scope of the present invention.

Further as will be recognized by those skilled in the art upon review of the present disclosure, stringers <NUM> and other components of shipping pallet <NUM> may be further modified to have desired properties. For example, the stringer <NUM> or other components may be wrapped with a paper or plastic or may be treated, at least in part, with, inter alia, fire retardants, insecticides, pesticides, fungicides, and waterproofing to inhibit deterioration. Other materials such as metal foils, plastics, resin impregnated paper, and other fibrous materials such as fibrous glass materials may also be incorporated into various implementations of shipping pallet <NUM>.

Claim 1:
A method for simultaneously manufacturing a plurality of stringers for a pallet from sheets of corrugate, comprising:
providing a plurality of corrugate sheets;
die cutting each corrugated sheet (<NUM>) of the plurality of corrugate sheets (<NUM>) to form a plurality of stringer shape sheets (<NUM>), each stringer shape sheet (<NUM>) having a plurality of parallel stringer sections (<NUM>) defined by cuts from an upper surface through the lower surface of the plurality of corrugate sheets (<NUM>);
aligning the plurality of stringer shape sheets (<NUM>) to superimpose the shape of the plurality of parallel stringers (<NUM>) on the adjacent stringer shape sheets (<NUM>);
bonding the plurality of stringer shape sheets (<NUM>) to form a laminated corrugate stringer block (<NUM>); characterised in that
each stringer section (<NUM>) on each stringer shape sheet (<NUM>) is linked to an adjacent stringer section (<NUM>) formed in the same stringer shape sheet (<NUM>) by a plurality of shear bridges (<NUM>);
the laminated corrugate stringer block (<NUM>) comprising a plurality of stringers (<NUM>) linked by a plurality of shear bridges (<NUM>); and
severing the plurality of shear bridges (<NUM>) to release one or more stringers (<NUM>) from the corrugate block (<NUM>).