WO2000020290A1

WO2000020290A1 - High-strength collapsible pallet with self-aligning construction

Info

Publication number: WO2000020290A1
Application number: PCT/US1999/023436
Authority: WO
Inventors: Robson T. Young, Jr.
Original assignee: Young Robson T Jr
Priority date: 1998-10-08
Filing date: 1999-10-07
Publication date: 2000-04-13
Also published as: AU6295499A

Abstract

A cellolosic pallet (100) is described wherein a cellulosic pallet deck (202) is supported by collapsible tubular support members (204, 206, 302) having rectangular cross-sections. The pallet has a main portion including the pallet deck and a series of flaps extending from the lateral sides of the pallet deck, these flaps being foldable to define outer support members (204, 205). The pallet also includes a central portion including a central support member (302) and side flaps extending from the lateral sides of the central support member. The side flaps are sized and configured so that when the central support member is installed between the outer support members with its side flaps in abutment with the outer support members, all support members are formed in parallel and simultaneously collapsible relation. Cellulosic support blocks (600) may be inserted within the lengths of the support members to impart enhanced strength. Additionally, cellulosic crossbeams (400) may be installed beneath the pallet deck to extend perpendicularly to the support members, with the support members and support blocks bearing insertion slots wherein the crossbeams are received.

Description

HIGH-STRENGTH COLLAPSIBLE PALLET WITH SELF- ALIGNING CONSTRUCTION

Inventor: Robson T. Young, Jr.

Cross-Reference to Related Applications

This application claims priority under 35 USC § 119(e) to U.S. Provisional Patent Application Serial No. 60/103,490 filed October 8, 1998, the entirety of which is incorporated by reference herein.

Field of the Invention

This disclosure concerns an invention relating generally to pallets for supporting cargo, and more specifically to pallets made of cellulosic sheets (e.g., paper, cardboard, fiberboard, corrugated cardboard, etc.).

Background of the Invention

Pallets are commonly used to support cargo. This disclosure concerns cellulosic pallets of exceptionally high strength which may be provided in flat form for storage and transport, and folded erect to pallet form at locations of use. As an exemplary collapsible cellulosic pallet, consider U.S. Patent 5,222,444 to Youell, Jr. et al. , specifically at Figs. 7 and 8. Fig. 7 of Youell, Jr. et al. illustrates an erect pallet having three beam-like collapsible support members having rectangular cross- sections. Two outer support members are aligned along opposite sides of the bottom of the pallet deck and a central support member extends along the bottom of the pallet deck parallel to the outer support members. The rectangular shape of the support members allows them to be collapsed by folding them as illustrated in Fig.

8 of Youell, Jr. et al , so that their opposing vertical sidewalls and opposing horizontal floors and ceilings are all aligned along substantially the same plane. Other examples of patents which illustrate pallets designed for relatively rapid construction and disassembly and/or for collapsibility are illustrated in U.S. Design Patent 370, 762; U.S. Patent 2,446,914 to Fallen et al. ; U.S. Patent 2,493,562 to

Yarman; U.S. Patent 2,665,096 to Vogel; U.S. Patent 3,026,078 to Simkins; U.S. Patent 3,434,435 to Achermann et al U.S. Patent 3,628,469 to Neitzke; U.S. Patent 3,911,834 to Quaintance; U.S. Patent 3,940, 101 to Heid lbach; U.S. Patent 3,952,672 to Gordon et al ; U.S. 4,714,026 to Yamaguchi et al ; U.S. Patent 4,863,024 to Booth; U.S. Patent 4,927,026 to Gossler et al ; U.S. Patent 4,949,898 U.S. Patent 5,176,090 to Robens et al ; U.S. Patent 5,195,440 to

Gottlieb; U.S. Patent 5,222,444 to Youell, Jr. et al; U.S. Patent 5,230,291 to Juvik-Woods; U.S. Patent 5,269,219 to Juvik-Woods; U.S. Patent 5,285,731 to Mclntyre; U.S. Patent 5,320,048 to Feiner, U.S. Patent 5,327,839 to Herring et al; U.S. Patent 5,329,861 to McCarthy; U.S. Patent 5,339,746 to Vannatta; U.S. Patent 5,377,600 to Speese et al; U.S. Patent 5,441, 154 to Youell, III; U.S. Patent

5,469,795 to Moorman; U.S. Patent 5,503,085 to Rozek; U.S. Patent 5,517,926 to Young, Jr.; U.S. Patent 5,562,048 to Gottlieb; U.S. Patent 5,592,885 to Young, Jr. et al; U.S. Patent 5,809,903 to Young, Jr.; and U.S. Patent 5,816,173 to Warneford, as well as European Patent Applications 183140 and 334329; French Patent Applications 2,158,447; 2,583,383; 2,260,503; and 2,691,699; German utility models (Gebrauchsmusteren) 9006016.4 and 92 16776.4; and British Patent 779,020.

Pallets such as those of Youell, Jr. et al must be carefully assembled if they are to be rapidly erected to pallet form. If a support member is not properly formed with a precisely rectangular cross-section — that is, so that its opposing vertical sidewalls are parallel, and its opposing horizontal floor and ceiling are parallel — it cannot unfold or collapse because the sidewalls and floor/ceiling will act as a truss. It is evident that a support member can only be unfolded or collapsed if its vertical sidewalls and horizontal floor/ceiling are respectively parallel. In order to guarantee such an arrangement, the parts of each support member must be carefully aligned and glued together during construction, and therefore fairly time-consuming assembly steps are required if the pallet is to be repeatedly erected and collapsed.

Similarly, failure to align all of the support members in a precisely parallel manner when they are being adhered to the pallet deck can also make it difficult to erect or collapse the pallet. If the vertical walls of one support member (e.g. , the support member 46 in Figs. 7-8 of Youell, Jr. et al.) are not parallel with respect to the vertical walls of another support member (e.g. , support member 48), these support members are incapable of being simultaneously collapsed by pushing on one side of the pallet, or simultaneously erected by pushing on one side of the pallet. Thus, time and care must also be taken during assembly to ensure that the support members are parallel. Collapsible pallets such as those of Youell, Jr. et al. must also be carefully assembled if they are to perform with maximum strength. Two types of strength are important for collapsible pallets: the load-bearing strength of the pallets, that is, their ability to withstand compression loads exerted vertically downward on the deck of the pallets; and their "side-shifting" strength, that is, their ability to withstand horizontally-oriented forces without collapsing. When assembling a collapsible pallet, there are three major considerations that must be kept in mind to maximize load-bearing and side-shifting strength.

First, assembly of collapsible pallets with misaligned parts, e.g., an improperly formed support member with non-parallel opposing walls, can cause excess wear and premature failure. This is particularly true because repeated collapsing and erection of improperly assembled pallets creates unintended fold lines which are subject to ripping under both side-shifting and compression loads, and which may also cause premature collapse. This is particularly true when side- shifting forces are present. Second, if the sides and ends of the support members are not precisely aligned with the edges of the pallet deck, the exposure of the seams between the deck and the support members is exaggerated. This makes it easier for cargo or other objects to catch the deck and/or support members and cause one to tear from the other. Third, failure to properly center the central support member and/or align the outer support members along the edges of the pallet deck can also affect the pallet's durability. If the central support member is not centered, one side of the pallet will have lesser load-bearing capacity. If this side of the pallet fails, the pallet may dump its cargo to one side off the pallet deck. Other factors affect strength as well, most particularly, the means by which the support members are maintained in an erect condition. Such means are generally provided by crossbeams or "stringers" which extend across adjacent support members to keep them maintained in a fixed spaced relation, and/or by support blocks which insert into the interior of the support members and which maintain the walls of the support members to maintain them in spaced relation. Ideally, a pallet will allow both types of support means so that either type may be used and the use of the other type is optional. Where support blocks are used, they should ideally be easily inserted and removed from the pallet for easier erection and collapsing of the pallet; they should be difficult to dislodge from the pallet during use (an event which could cause accidental collapse and damage to cargo); and they should be unfoldable to a flat form, or otherwise capable of collapsing to a compact form for easier storage.

Summary of the Invention

The present invention is directed to a cellulosic pallet having an exceptionally strong self-aligning construction, that is, it may be rapidly assembled with all parts automatically aligned for maximum durability (and also for collapsibility, if such is desired). In particular, the pallet is believed to have a higher degree of strength than any of the aforementioned cellulosic pallets having comparable assembly times. To enhance the reader's understanding, the following summary of the invention will make reference to the embodiments shown in the drawings, which are discussed at greater length in the later Detailed Description of the Invention.

Referring to FIGS. 1 and 2, a preferred pallet in accordance with the invention includes a main portion which includes (1) a generally planar pallet deck and two outer support members (that is, support members that each rest beneath the pallet deck at its opposing lateral sides); (2) a central support portion which includes one or more central support members which rest between the outer support members; (3) support blocks which are each sized to fit within the internal channel of one of the support members (see FIG. 3 for an illustration of a support block 600 removed from its support member); and (4) crossbeams extending beneath the pallet deck to intersect at least two of the elongated support members (again see FIG. 3 for a particularly illustrative view of a crossbeam 400). Most preferably, the crossbeams and support members both have the same height beneath the pallet deck (i.e., both extend between the bottom of the pallet deck and the floor) across the major portions of their lengths so that they both serve to support the pallet deck.

In the main portion, the outer support members are defined by a series of integrally connected sections extending from (and integrally connected to) the lateral sides of the pallet deck. Each series of sections includes an outer sidewall section, a floor section, an inner sidewall section, and a deck section. The sections are separated by fold lines, all of which are parallel. The sections may be folded beneath the pallet deck so that the deck section is in abutment with the underside of the pallet deck, thereby placing the inner and outer sidewall sections in opposing relation and also placing the floor section opposite the pallet deck (as seen in FIGS.

1-3). This defines an internal channel extending within the length of each outer support member (as shown at 318 in FIG. 3).

The central support portion (see particularly FIGS. 2-3) includes at least one central support member having opposing sidewalls with a floor therebetween, and side flaps extending from the sidewalls and terminating in lateral edges. The floor, sidewalls, and side flaps are all separated by fold lines, which are parallel to each other and additionally to the lateral edges of the side flaps. The sidewalls are sized to have the same height, and the side flaps are sized so that when they are placed in parallel relation to the floor at maximum distance therefrom, their lateral edges fit in abutment with the outer support members when inserted therebetween. As a result, when the central support portion is placed in an operating position wherein the side flaps are in abutment with the outer support members, the sidewalls of the central support member are placed in parallel opposing relation and the fold lines pf the central support member are parallel to the fold lines of the outer support members. In other words, all support members are made parallel and simultaneously collapsible. Because this is accomplished by merely placing the side flaps in abutment with the outer support members, the central support portion is said to be self-aligning because it requires virtually no effort to form support members which are parallel and simultaneously collapsible. As can be seen particularly well in FIGS. 2 and 3 (as well as in the support block blank 600 and crossbeam blank 400 of FIG. 4), the support blocks and crossbeams are preferably each formed of a single piece of cellulosic material which is divided into a series of adjacent strips by an array of parallel fold lines, whereby the strips may be accordion-folded about the fold lines to form the support blocks and crossbeams. As a result, the support blocks and crossbeams are essentially each formed of a "stack" of cellulosic material with extremely high strength in directions oriented along the planes of the cellulosic material. However, at the same time the support blocks and crossbeams will be somewhat compressible in directions oriented perpendicularly to the planes of the strips, particularly where the cellulosic material is corrugated cardboard. As can be seen particularly well in FIG. 3, the support members and crossbeams include complimentary insertion slots whereby the crossbeam is received within the insertion slots of the support members, and the support members are simultaneously received within the insertion slots of the crossbeams. In embodiments of the pallet such as the one illustrated in FIGS. 1-3, the interlocking arrangement of the support members and crossbeams is beneficial insofar as no adhesive is necessary to hold the pallet together in the condition of FIGS. 1-2: once the crossbeam is inserted, the pallet is folded together in a constructed state. This arrangement is promoted by sizing the crossbeam insertion slots within the support members slightly more narrow than the widths of the crossbeams themselves. When the crossbeams are formed of corrugated cardboard or similar cellulosic material, insertion of the crossbeams within the crossbeam insertion slots of the support members has the effect of slighύy compressing the width of the crossbeams, thereby firmly wedging the crossbeams within the support members. This helps to later prevent a crossbeam from easily being dislodged from the slots in the support members. Further, it helps to lock the crossbeams and the support members into an extremely rigid grid pattern which is highly resistant to bending in all directions, and which has exceptionally high load-supporting capacity.

The load capacity is particularly enhanced when the planes of the cellulosic sheets forming the crossbeams and support blocks are oriented perpendicularly to the pallet deck, since the cellulosic sheets are not as compressible in this direction.

As shown in FIGS. 2 and 3, each support member preferably includes a support member valley defined therein at the bottom of the support member (and pallet), the support member valley being oriented generally perpendicular to the lengths of the support members and parallel to the lengths of the crossbeams. On the outer support members, the support member valleys may be defined by openings formed on the outer sidewall sections, floor sections, and inner sidewall sections; on the central support member, the support member valleys may be defined by openings formed on its sidewalls and floor. The support blocks received within these support members include complementary valleys, as can be most easily seen in FIG. 3. Thus, when the support blocks are inserted within the internal channels of the support members, the support member valleys are left open to accommodate the arms of a forklift. Additionally, inclusion of the valleys on the support blocks decreases the contact area between the support blocks and support members when the support blocks are inserted within the support members, thereby decreasing friction and making the support blocks easier and faster to install. Further, the valleys reduce the weight and material expense of the pallet without significantly decreasing its load-bearing strength.

Similarly, the crossbeams each preferably include a valley situated at the bottom of the crossbeam (and pallet) which is oriented perpendicularly to the lengths of the crossbeams (and parallel to the support members). Each valley in a support member is preferably situated between two crossbeams, and each valley within a crossbeam is preferably situated between two support members.

Other significant advantages of the pallets described herein are that the support members are highly resistant to tearing off of the pallet deck, a problem which is commonly encountered in prior pallets; and the pallet deck effectively has a double-layer construction over the majority of its surface, thereby imparting greater effective strength to the pallet deck.

Further advantages, features, and objects of the invention will be apparent from the following detailed description of the invention in conjunction with the associated drawings.

Brief Description of the Drawings FIG. 1 is a top perspective view of the pallet of the present invention. FIG. 2 is a bottom perspective view of the pallet of FIG. 1. FIG. 3 is a bottom perspective view of the pallet of FIG. 1 shown with only one crossbeam 400 (shown removed), and with one support block 600 shown removed.

FIG. 4 is a view of the pallet of FIGS. 1-3 shown in disassembled and unfolded form, with only one crossbeam 400 and one support block 600 being shown.

Detailed Description of the Invention

In the drawings, wherein the same or similar features of the invention are designated in all Figures with the same reference numerals, a first embodiment of the pallet of the present invention is illustrated in assembled form in FIGS. 1 and 2 at 100. As is best shown by FIG. 3, which illustrates the pallet 100 from its underside in partially disassembled form, the pallet 100 includes three main portions: an outer support portion 200, a central support portion 300, and crossbeams 400. Each of these will now be discussed in turn.

The outer support portion 200 includes a pallet deck 202 and two outer support members 204 and 206, each resting beneath the pallet deck 202 at its opposing lateral sides. As best shown by FIG. 4, wherein the outer support portion 200 is illustrated in unassembled (i.e., blank) form, the outer support members 204 and 206 are defined by a series of sections extending from the lateral sides of the pallet deck 202. These sections include an outer sidewall section 208; a floor section 210; an inner sidewall section 212; and a deck section 214, wherein the sections 208, 210, 212, and 214 collectively extend between opposing outer lateral edges 216 of the deck sections 214. The sections 208, 210, 212, and 214 are separated from each other (and from the pallet deck 202) by fold lines 218 (this reference numeral being shown only in FIG. 4).

It is intended that the sections 208, 210, 212, and 214 be folded inwardly along the fold lines 218 to define generally tubular outer support members 204 and 206 having internal channels 220 therein, thereby converting the blank outer support portion 200 (FIG. 4) to the assembled outer support portion 200 illustrated in FIGS.

1-3. However, in order to make the outer support portion 200 self-aligning — that is, to automatically make the outer support members 204 and 206 parallel, with their respective inner/outer sidewall sections 208/212 and floor/deck sections 210/214 aligned in parallel relation so that both of the outer support members 204 and 206 are simultaneously collapsible — the sections 208, 210, 212, and 214 that form the outer support members 204 and 206 must meet certain specifications. First, all fold lines 218 must be parallel. This guarantees that the outer support members 204 and 206 will be parallel when the sections 208, 210, 212, and 214 are folded along the fold lines 218.

Second, the outer and inner sidewall sections 208 and 212 must be formed with approximately the same height (as measured laterally from the pallet deck 202 in FIG. 4), and the floor and deck sections 210 and 214 must be formed with approximately the same width (also as measured laterally from the pallet deck 202 in FIG. 4). Ideally, to be exact, the inner sidewall section 212 should be formed slightly shorter than the outer sidewall section 208, and the deck section 214 should be slightly shorter than the floor section 210, by a distance equal to the thickness of the material used to construct the outer support portion 200. This more precise sizing makes the outer/inner sidewall sections 208/212, as well as the floor/deck sections 210 and 214, more precisely aligned in parallel relation. While this degree of precision may not seem significant, it can contribute significantly to the strength and operating lifetime of the pallet 100. By forming the outer support members 204 and 206 with dimensions that fairly precisely meet these specifications, the inner/outer sidewall sections 208/212 and floor/deck sections 210/214 will automatically be aligned in parallel relation when the face of the deck section 214 is folded into abutment with the pallet deck 202, with its outer lateral edge 216 in abutment with the outer sidewall section 208. This ensures that the outer support members 204 and 206 are easily and simultaneously collapsed when the pallet is pushed in a lateral direction, and when no objects rest within the internal channels 220 of the outer support members 204 and 206. Additionally, the user assembling the outer support portion 200 does not need to pay particularly close attention to the alignment of the sections 208, 210, and 212 during assembly because it is an easy matter to place the deck section 214 in abutment with both the pallet deck 202 and the outer sidewall section 208. Adhesive may be used to affix the deck section 214 to the pallet deck 202 and/or the outer sidewall section 208 if permanency is desired.

The central support portion 300 includes a central support member 302 having opposing sidewalls 304 and 306 with a floor 308 therebetween, and side flaps 310 and 312 extending from the lateral edges of the sidewalls 304 and 306 and terminating in lateral edges 314. The sidewalls 304 and 306, the floor 308, and the side flaps 310 and 312 are all separated by fold lines 316 (this reference numeral being shown only in FIG. 4), which are all parallel with respect to each other and also parallel to the lateral edges 314. It is desirable to make the central support portion 300 rapidly installable between the outer support members 204 and 206 of the outer support portion 200, with the central support member 302 being parallel to (and thus simultaneously collapsible with) the outer support members 204 and 206. This is done by sizing the sidewalls 304 and 306 so that they have the same height, and by also sizing the floor 308 and side flaps 310 and 312 such that when they are all placed in parallel relation with the floor 308 at maximum distance from the side flaps 310/312 when the lateral edges 314 of the side flaps 310 and 312 are fit in abutment with the inner walls 212 of the outer support members 204 and 206. Thus, when the assembler applies adhesive to the side flaps 310 and 312 and then inserts them between the outer support members 204 and 206 and in abutment with the pallet deck 202, the central support member 302 will automatically be formed with the sidewalls 304 and 306 are in parallel relation, and wherein the sidewalls 304 and 306 and floor 308 are also in parallel relation to each other and to the pallet deck 202. The central support member 302 is therefore parallel and simultaneously collapsible with the outer support members 204 and 206, and includes an internal channel 318 between the pallet deck 202 and floor 308, and between the sidewalls 304 and 306.

From the aforementioned arrangement of the outer support portion 200 and central support portion 300, it will be understood that the pallet 100 can be constructed in exceptionally rapid fashion without fear of misalignment, that is, non- parallel support members, support members which are not simultaneously collapsible, or support members which have lateral or longitudinal edges which are not aligned with the edges of the pallet deck 202. This self-aligning feature simultaneously reduces both the time needed to construct the pallet 100, and the possibility that a misaligned (and thus less durable) pallet will be constructed.

Support member valley openings 500 (see particularly FIGS. 2 and 4) are formed on the outer sidewall section 208, floor section 210, and inner sidewall section 212 of the outer support members 204 and 206. Such support member valley openings 500 are also formed on the sidewalls 304/306 and floor 308 of the central support member 302. As a result, when the support members 204, 206, and 302 are assembled from the form of FIG. 4 to the form of FIG. 2, arch-like support member valleys 502 are formed in the support members between the plane of the pallet deck 202 and the plane of the floor section 210 and floor 308. These support member valleys 502 extend through the support members 204, 206, and 302 in directions generally perpendicular to their lengths. As a result, forklift tines may be inserted through these support member valleys 502 so that the tines extend through and under all of the support members 204, 206, and 302, thereby allowing the forklift tines to lift the pallet 100 via its support members.

In similar fashion, support member insertion slot openings 504 (see particularly FIGS. 3 and 4) are formed on the outer sidewall section 208, floor section 210, and inner sidewall section 212 of the outer support members 204 and 206, as well as on the sidewalls 304/306 and floor 308 of the central support member 302. When the support members 204, 206, and 302 are assembled to the form of FIG. 3, support member insertion slots 506 are formed in the support members between the plane of the pallet deck 202 and the plane of the floor section 210 and floor 308. The support member insertion slots 506 extend through the support members 204, 206, and 302 along axes oriented generally perpendicular to the lengths of the support members, and as will be discussed below, they accommodate the insertion of the crossbeams 400. The support member insertion slots 506 are shaped with generally rectangular support member insertion slot bottoms 508 (i.e., those portions of the slots 506 resting closest to the pallet deck 202) and support member slot insertion slot mouths 510 which converge inwardly towards the support member insertion slot bottoms 508. The slot mouths 510, at their widest point, have a width which is approximately the same as the width of the crossbeams 400 so as to allow the crossbeams 400 to be easily inserted. However, the narrower portions of the support member insertion slot mouths 510 (as well as the support member insertion slot bottoms 508) are sized with a width slightly smaller than that of the insertable crossbeams 400. As a result, the crossbeams 400 are wedged tightly into the support member insertion slots 506 during insertion, and they will experience some compression. This compression is easily accommodated where the crossbeams 400 are made of multi-ply corrugated cardboard, but where less compressible material is used for the crossbeams 400, it may be desirable to size the insertion slots 506 so that they provide lesser or no compression of the crossbeams 400. To impart additional strength to the pallet 100 and prevent its collapse when in standard use, support blocks 600 are preferably provided within the internal channels 220 of the outer support portion 200 (i.e., between the sections 208, 210, 212, and 214 of the outer support members 204 and 206), and also within the internal channel 318 of the central support portion 300 (i.e., between its opposing sidewalls 304 and 306, and also between its floor 308 and the pallet deck 202). The support block 600 is sized to occupy all or a substantial part of the interiors of the support members 204, 206, and 302 when resting axially within the support members. As illustrated in FIGS. 3 and 4, the support block 600 may be formed of a paperboard support block blank which is divided into segments 602 by fold lines 604, the segments 602 having substantially similar sizes and having mirror-image symmetric configurations with respect to adjacent segments 602 across bounding fold lines 604. This allows the blank support block 600 of FIG. 4 to be folded in accordion fashion about the fold lines 604 to construct the assembled support block 600 shown in FIG. 3. The support block 600 may then be snugly fit within the outer support members 204 and 206 and the central support member 302, with the fit preferably being sufficiently snug that the support block 600 will be substantially resistant to slipping within the support members.

The support block 600 includes support block valleys 606 (best illustrated in FIG. 3) which are defined in the surfaces of the support block 600. As FIG. 4 illustrates, these support block valleys 606 are formed by defining support block valley openings 608 on the support block blank which combine to form the support block valleys 606 when the support block blank is folded. The support block valleys 606 are formed in conformity with the support member valleys 502 in the outer support members 204 and 206 and the central support member 302 so that the support member valleys 502 are not obstructed along axes perpendicular to the support members and parallel to the pallet deck 202. In similar fashion, as shown in FIG. 4, support block insertion openings 610 are formed on the support block blank which combine to form support block insertion slots 612 (best illustrated in FIG. 3) in the surfaces of the support blocks 600 when the support block blank is folded. The support block insertion slots 612 are formed in conformity with the insertion slots 506 in the support members 204, 206, and 302 so that the insertion slots 506 are not obstructed along axes perpendicular to the support members and parallel to the pallet deck 202.

The crossbeam 400, which is best shown in FIG. 3, is preferably formed of multiple layers of corrugated cardboard in the same manner as the support blocks

600. The length of the crossbeam 400, as measured between its opposing ends 402, is preferably the same as that of the pallet 100 between its lateral edges. The crossbeam 400 has a top surface 404 with depressed regions or slots 406 corresponding to the insertion slots in the support members 204, 206, and 302, a bottom surface 408 having crossbeam valleys 410 defined therein for insertion of the tines of a forklift, and opposing sides 412 which, as noted above, are spaced by approximately the width of the slot openings 510 at their widest point. When the crossbeam 400 is inserted into the insertion slots 506, it extends across the underside of the pallet 100 from one of its sides to the other, its top surface rests closely adjacent to the side flaps 310 and 312 of the central support portion 300, and its bottom surface 408 rests in generally the same plane as the floor sections 210 of the outer support members 204 and 206 and the floor 308 of the central support member

302. The depressed regions/slots 406 on the top surface 404 rest in abutment with the bottom of the insertion slots 506, whereas the remainder of the top surface 404 holds the side flaps 310 and 312 of the central support portion 300 in abutment with the pallet deck 202. The converging insertion slots 506 maintain the crossbeam 400 tightly wedged therein, thereby preventing the crossbeam 400 from falling out of the bottom of the pallet 100 when it is lifted. It is notable that since the insertion slots

506 maintain the crossbeam 400 on the pallet 100, and since the crossbeam 400 maintains the side flaps 310 and 312 of the central support portion 300 in abutment with the pallet deck 202, it is not necessary to use adhesives or other structures/materials to hold the pallet 100 together if these are not desired.

It is understood that the pallet 100 is shown and described above to illustrate a particularly preferred embodiment of the invention, and the invention is not limited to this embodiment alone. Various modified versions of the pallet 100 are also within the scope of the invention, and examples of these modifications follow.

First, while the support blocks 600 and crossbeams 400 were described above as being folded from blanks in accordion-folded fashion, other folding arrangements may be used as well, e.g., the segments 602 of the support blocks 600 could be folded in spiral fashion about the fold lines 604.

Second, it should be understood that the support blocks 600 need not be inserted within the support member internal channels 220 and 318 after the support members 204, 206, and 302 are constructed. Instead, they can be placed on the blank of the outer support portion 200 or the central support portion 300, and the blanks can be folded to form the support members 204, 206, and 302 directly around them. If collapsibility is not required, this procedure can be followed after applying adhesive to the support blocks 600 and the blanks of the outer support portion 200 and central support portion 300 so that the support blocks are firmly adhered within the internal channels 220 and 316.

Third, it should be understood that the lateral widths of the blanks of the outer support portion 200 and the central support portion 300 can be varied, and the lateral edges 216 and lateral edges 314 of the blanks may be situated at different locations after the support members 204, 206, and 302 are formed. To illustrate, the deck sections 214 of the outer support members 204/206 could be situated in parallel abutment with the pallet deck 202 outside the outer support members 204 and 206, and could extend inwardly towards the center of the pallet 100 to have their lateral edges 216 contact the lateral edges 314 of the central support portion 300 at its side flaps 310 and 312. As a result of this arrangement, unlike the pallet 100 of the Drawings, the outer internal channels 220 would be bounded by the pallet deck

202, the outer sidewall section 208, the floor section 210, and the inner sidewall section 212, similarly to the manner in which the pallet deck 202, the sidewalls 304 and 306, and the floor 308 of the central support member 302 surround the central internal channel 318. This arrangement may yield superior strength in comparison to the pallet 100 because the support blocks 600, when inserted within the outer internal channels 220, would rest partially within the plane of both the deck sections 214 of the outer support members 204/206 and the side flaps 310/312 of the central support portion 300. Since the deck sections 214 and side flaps 310/312 effectively form a part of the pallet deck 202 when joined to the pallet deck 202, the support blocks 600 would essentially be inserted into a portion of the thickness of the effective pallet deck and would therefore more effectively be affixed within the pallet 100. Provided the side flaps 310/312, sidewalls 304 and 306, and floor 308 of the central support member 302 are sized as shown in FIGS. 1-3 in relation to the sections 208, 210, 212, and 214 of the outer support members 204/206 - that is, so that the outer support members 204 and 206 and the central support member 302 are formed for simultaneous collapsibility, with the side flaps 310 and 312 of the central support portion 300 abutting the outer support members 204 and 206 — the pallet

100 will still be self-aligning during construction, erection, and collapsing of the pallet 100.

The invention is not intended to be limited to the preferred embodiments described above, but rather is intended to be limited only by the claims set out below. Thus, the invention encompasses all alternate embodiments that fall literally or equivalently within the scope of these claims. It is understood that in the claims, means plus function clauses are intended to encompass the structures described above as performing their recited function, and also both structural equivalents and equivalent structures. As an example, though a nail and a screw may not be structural equivalents insofar as a nail employs a cylindrical surface to secure parts together whereas a screw employs a helical surface, in the context of fastening parts, a nail and a screw are equivalent structures.

Claims

CLAIMSWhat is claimed is:

1. A pallet comprising: a. a generally planar pallet deck including opposing top and bottom surfaces; b. two or more elongated support members affixed to the bottom surface of the pallet deck, each support member including an internal channel extending through its length; c. one or more support blocks, each support block being sized to fit within the internal channel of one of the support members; d. one or more crossbeams, each crossbeam extending below the pallet deck between at least two of the elongated support members.

2. The pallet of claim 1 wherein two of the support members are each integrally formed with the pallet deck, these support members each being formed of a series of adjacent flaps which are folded beneath the pallet deck to define one internal channel.

3. The pallet of claim 2 wherein the support members and the crossbeams include complementary slots defined therein, whereby the crossbeams may be moved along axes oriented generally peφendicularly to the pallet deck to intersect the support members, with the crossbeams received within the slots within the support members and the support members received within the slots within the crossbeams.

4. The pallet of claim 3 wherein the flaps of the support members are unfoldable until the crossbeams are received within the slots in the support members and the support members are received within the slots in the crossbeams.

5. The pallet of claim 3 wherein the crossbeams are compressed when received within the slots within the support members, the crossbeams thereby being resistant to dislodgement therefrom.

6. The pallet of claim 3 wherein the slots defined within the support members include slot openings descending to slot bottoms, wherein the slot openings are wider than the slot bottoms.

7. The pallet of claim 6 wherein the support blocks and crossbeams are each formed of a series of adjacent strips of material separated by fold lines, wherein the strips are accordion-folded about the fold lines.

8. The pallet of claim 1 wherein the support members and the crossbeams include complementary slots defined therein, whereby the crossbeams may be moved along axes oriented generally perpendicularly to the pallet deck to intersect the support members, with the crossbeams received within the slots within the support members and the support members received within the slots within the crossbeams.

9. The pallet of claim 8 wherein the crossbeams are compressed when received within the slots within the support members, and are thereby resistant to dislodgement therefrom.

10. The pallet of claim 8 wherein the slots defined within the support members include slot openings descending to slot bottoms, wherein the slot openings are wider than the slot bottoms.

11. The pallet of claim 8 wherein two of the support members are each integrally formed with the pallet deck, these support members each being formed of a series of adjacent flaps which are folded beneath the pallet deck to define one internal channel, wherein the flaps are maintained in a folded state by inserting the crossbeams within the slots in the support members and inserting the support members within the slots in the crossbeams.

12. The pallet of claim 8 wherein: a. each support member includes:

(1) a support member top situated adjacent the pallet deck,

(2) a support member bottom situated opposite the pallet deck, and

(3) support member sidewalls extending between the pallet deck and the support member bottom, the support member sidewalls and support member bottom including a support member valley defined therein, the support member valley being oriented generally perpendicularly to the length of the support member; b. each crossbeam includes:

(1) a crossbeam top situated adjacent the pallet deck,

(2) a crossbeam bottom situated opposite the pallet deck, and (3) crossbeam sides extending between the pallet deck and the support member bottom, the crossbeam sides and crossbeam bottom including a crossbeam valley defined therein, the crossbeam valley being oriented generally perpendicularly to the length of the crossbeam.

13. The pallet of claim 1 wherein the support blocks and crossbeams are each formed of a series of adjacent strips of material separated by fold lines, wherein the strips are accordion-folded about the fold lines.

14. The pallet of claim 1 wherein: a. each support member includes:

(1) a support member top situated adjacent the pallet deck, (2) a support member bottom situated opposite the pallet deck, and

(3) support member sidewalls extending between the pallet deck and the support member bottom, the support member sidewalls and support member bottom including a support member valley defined therein oriented generally perpendicularly to the length of the support member; b. each crossbeam includes:

(1) a crossbeam top situated adjacent the pallet deck, (2) a crossbeam bottom situated opposite the pallet deck, and

(3) crossbeam sides extending between the pallet deck and the support member bottom, the crossbeam sides and crossbeam bottom including a crossbeam valley defined therein oriented generally perpendicularly to the length of the crossbeam.

15. The pallet of claim 14 wherein: a. each support member valley is situated between two crossbeams; and b. each crossbeam valley is situated between two support members.

16. The pallet of claim 14 wherein the support members and the crossbeams include complementary slots defined therein, whereby the crossbeams may be moved along axes oriented generally perpendicularly to the pallet deck to intersect the support members, with the crossbeams received within the slots within the support members and the support members received within the slots within the crossbeams.

17. The pallet of claim 16 wherein the crossbeams are compressed when received within the slots within the support members.

18. The pallet of claim 16 wherein the slots defined within the support members include slot openings descending to slot bottoms, wherein the slot openings are wider than the slot bottoms.

19. The pallet of claim 14 wherein the support blocks and crossbeams are each formed of a series of adjacent strips of material separated by fold lines, wherein the strips are accordion-folded about the fold lines.

20. The pallet of claim 14 wherein two of the support members are each integrally formed with the pallet deck, these support members each being formed of a series of adjacent flaps which are folded beneath the pallet deck to define one internal channel.