A PALLET AND METHOD OF MANUFACTURING A PALLET

Abstract

The present invention is directed to a pallet formed from a plurality of layers of sheeting. the pallet comprising: one or more upper liner layers of sheeting; two or more feet; a lower supporting layer of sheeting including a plurality of foldable flaps; wherein the foldable flaps are adapted to locate and hold the feet between the lower supporting layer and the upper liner layers. The invention is also directed to a method of manufacturing a pallet, the method including the following steps: forming a deck comprising one or more upper liner layers; forming a plurality of feet; forming a lower supporting layer, wherein the lower supporting layer includes a plurality of foldable flaps adapted to locate and hold the feet between the lower supporting layer and the upper liner layers; joining the plurality of feet to the lower supporting layer; and joining the deck to the plurality of feet.

Claims

1. A pallet formed from a plurality of layers of sheeting, the pallet comprising: one or more upper liner layers of sheeting; two or more feet; a lower supporting layer of sheeting including a plurality of foldable flaps; wherein, the foldable flaps are adapted to locate and hold the feet between the lower supporting layer and the upper liner layers.

2. The pallet according to claim 1, wherein the foldable flaps are adapted to fold beside an outer side wall of one or more of the feet.

3. The pallet according to claim 1, wherein one or more of the foldable flaps are cut out of the lower supporting layer.

4. The pallet according to claim 1, wherein the foldable flaps are configured to extend along at least part of, and be joinable to, the feet.

5. The pallet according to claim 1, wherein the feet each comprise a folded sheet.

6. The pallet according to claim 5, wherein the folded feet sheets each include a segment that extends diagonally in a region between the lower supporting layer and the upper liner layers, in front view.

7. The pallet according to claim 6, wherein feet sheets each include a plurality of rectangular segments, one of which comprises a back-folded segment folded in a first direction, and another segment adjacent to the back-folded segment which is folded in a second direction that is opposite to the first direction.

8. The pallet according to claim 6, wherein all segments in each of the feet sheets, except for the back-folded segment, are folded in the second direction.

9. The pallet according to claim 6, wherein a plurality of the folded rectangular segments are adhered to each other, and the foldable flaps are joined to the liner layer and/or to the feet by adhesion.

10. The pallet according to claim 6 wherein side walls of the feet comprise at least two layers of segments.

11. The pallet according to claim 6 wherein the feet are formed from fluted sheeting and crease lines in the sheeting for forming the segments thereof are transverse to a flute direction of the fluted sheeting.

12. The pallet according to claim 1, wherein the sheeting comprises fluted sheeting that includes recesses, channels, patterned formations and/or corrugations in the flute.

13. The pallet according to claim 12, wherein there are at least two upper liner layers and the recesses, channels, patterned formations and/or corrugations in a first upper liner layer are offset from a second upper liner layer.

14. The pallet according to claim 1, wherein each foot comprises an elongate rectangular prism, and wherein the foldable flaps are formed in pairs of folding flaps.

15. (canceled)

16. The pallet according to claim 1, wherein one or more of the foldable flaps are bi-folding flaps, including a first crease adapted to fold near a lower part of a foot, and a second crease adapted to fold near a top part of the foot.

17. The pallet according to claim 16, wherein the bi-folding flaps include a first section adapted to extend vertically and perpendicular to a horizontal plane of the lower supporting layer, and a second section adapted to extend horizontally and parallel to the horizontal plane of the lower supporting layer; the first section being adapted to be connected to an outer vertical side wall of the feet; and the second section being adapted to be connected to a lowermost upper liner layer.

18. The pallet according to claim 1, wherein the foldable flaps are located on the lower supporting layer such that, when folded, they provide an opening in the lower supporting layer configured to receive a wheel of a pallet lifting tyne.

19. The pallet according to claim 1, wherein internal diagonal segment(s) of the foot, or feet, on a first side of the pallet extend in a first diagonal direction, and internal diagonal segment(s) of the foot, or feet, on a second side of the pallet extend in a second diagonal direction opposite to the first diagonal direction.

20. The pallet according to claim 1, wherein each of the upper liner layer(s), the supporting layer(s), and the feet are formed by the same type of sheeting.

21. A method of manufacturing a pallet, the method including the following steps: Forming a deck comprising one or more upper liner layers; Forming a plurality of feet; Forming a lower supporting layer, wherein the lower supporting layer includes a plurality of foldable flaps adapted to locate and hold the feet between the lower supporting layer and the upper liner layers; Joining the plurality of feet to the lower supporting layer; Joining the deck to the plurality of feet.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0082] Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments and preferred methods of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0083] FIG. 1 is a perspective view of upper liner layers, feet and a lower supporting layer, with flaps folded outwards, in accordance with a first preferred embodiment of the present invention;

[0084] FIG. 2 is a perspective view of the lower supporting layer of the first preferred embodiment of the present invention (flaps are unfolded);

[0085] FIG. 3 is a bottom perspective view of one of the feet of the first preferred embodiment of the present invention depicted in FIG. 1;

[0086] FIGS. 4A to 4D are illustrations of sheeting undergoing sequential, or step-wise, folding as part of a method of forming a foot in accordance with a preferred method of the invention;

[0087] FIGS. 5A to 5E are illustrations of the components of the pallet depicted in FIG. 1 being combined, in a step-wise manner, in accordance with a preferred method of the invention

[0088] FIG. 6 is a perspective view of a two-foot pallet in accordance with a further preferred embodiment of the present invention;

[0089] FIG. 7 is a perspective view of a three-foot pallet in accordance with a further preferred embodiment of the present invention;

[0090] FIG. 8 is a perspective view of four different configurations for pallet feet in accordance with further preferred embodiments of the present invention;

[0091] FIG. 9 is a perspective view of an alternative pallet foot in accordance with a further preferred embodiment of the present invention;

[0092] FIG. 10 is a bottom perspective view of a pallet in accordance with a further preferred embodiment of the invention;

[0093] FIGS. 11A and 11B are perspective views of a racking pallet and the racking pallet's constituent parts, in accordance with a further preferred embodiment of the present invention; and FIGS. 12A and 12B are perspective views of a 4-way entry pallet and the 4-way entry pallet's constituent parts, in accordance with a further preferred embodiment of the present invention.

DESCRIPTION OF EMBODIMENTS

[0094] It should be noted in the following description that like or the same reference numerals in different embodiments generally denote the same or similar features.

[0095] FIG. 1 depicts the principal components of a pallet 100 in accordance with a preferred embodiment of the invention. The pallet 100 includes two upper liner layers 10, 11, four feet 20, 21, 22, and 23, each in the shape of an elongate rectangular prism, and a lower supporting layer 30.

[0096] The feet 20, 21, 22, 23 extend across a length of the pallet 100, and the supporting lower layer 30 of sheeting comprises a base layer of the pallet 100. The two upper liner layers 10, 11 form the deck of the pallet 100, for receiving goods.

[0097] The lower supporting layer 30 comprises the base of the pallet 100, and includes 14 foldable flaps, most of which (but not all of which) are visible in FIG. 1. Edge flaps 40, 45, central flaps 50, 51 and two pairs of bi-folding flaps 60, 61, and 62, 63 are identified on FIG. 1.

[0098] Each of the flaps are more easily identified in FIG. 2, and these comprise: edge flaps 40 and 45, central flaps 50, 51 and 52, 53 and four pairs of bi-folding flaps, 60 and 61; 62 and 63; 64 and 65; and 66 and 67.

[0099] The flaps operate to locate and hold the feet 20, 21, 22, 23 in position in between the lower supporting layer 30 and the upper liner layers 10, 11.

[0100] Each of the foldable flaps 40, 45, 50 to 53, 60 to 67, are adapted to fold beside and abut an outer side wall of one or more of the feet 20 to 23. For example, edge flap 40 folds beside and abuts outer side wall 20A of the right-most foot 20 in FIG. 1. The flaps may also be adapted to fold around, and be joined to, a plurality of outer side walls of the feet.

[0101] Each of the foldable flaps 40, 45, 50 to 53, 60 to 67, are formed in pairs of folding flaps. The pairs are not necessarily contiguous or proximate to each other: edge flaps 40 and 45 are on opposing sides of the lower supporting surface 30.

[0102] Each of the foldable flaps 40, 45, 50 to 53, 60 to 67 is configured to extend along, and be joinable to, respective portions of the outer side walls of the feet 20, 21, 22, 23.

[0103] Most of the flaps, namely the central flaps 50 to 53 and the bi-folding flaps 60 to 67, are formed by cutting the lower supporting layer 30. This cutting may be performed by die-cutting. One benefit of the invention is that the flaps may be formed integrally with, and as part of the lower layer, and the gap(s) or opening(s) formed in the lower layer, so as to not significantly diminish the overall strength of the pallet, and enable the pallet to receive the wheels in the tynes of pallet lifting devices (for example, a manual pallet jack, pallet lifter, pallet stacker) to assist in the movement of the pallets. However, the invention is not limited to the flaps being cut-outs and forming such gaps or openings, and the flaps may be adhered or otherwise joined to the lower layer (and there may not by any such gaps or openings, in some embodiments of the invention).

[0104] Each of the feet 20 to 23, comprise a folded layer of sheeting, which is folded 10 times (see below reference to FIGS. 4A to 4D for detailed discussion about the folding process). Each of the feet include a segment that extends diagonally in the region between between the lower supporting layer 30 and upper liner layers 10, 11, when the feet are viewed from the front or back. The diagonal segment, 27B of the foot 22 is more clearly illustrated in FIG. 3. This arrangement is particularly strong when the diagonal segment is a back-folded segment as is the case for the feet 20 to 23.

[0105] Two of the feet 20, 21 have diagonal segments that extend in a first direction, and two of the feet 22, 23 have diagonal segments that extend in a second direction, opposing (transverse to) the first direction. The different diagonal direction between the feet is obtained when the feet 20, 21 (or 22, 23) are rotated around 180 degrees. The right-most feet 20, 21, each have diagonal segments that, in front view, extend between a lower left region and an upper right region of the respective foot 20, 21, and together with adjacent segments form the shape of the letter N when written backwards, or . The left-most feet 20, 21, each have diagonal segments that, in front view, extend between a lower right region and an upper left region of the respective foot 22, 23, and together with adjacent segments form the shape of the letter N. This feature of foot 22 is more clearly illustrated in FIG. 3.

[0106] Arrangements of the feet such as that depicted in FIG. 1, which have transverse diagonal segments, allow the forces acting on the diagonal back-folded segments to work against each other and spread the dynamic load that bears on the pallet 100 during use.

[0107] It will be appreciated that, in the non-limiting preferred embodiment of the feet depicted in FIGS. 1 and 3, in addition to the strengthening effect resulting from folding that increases the number of layers of the walls of each of the feet 20 to 23, the back-folds allow the sheeting material for each of the feet to work against itself wanting to come back to its opposite folding side, which it is unable to do because it is positioned in a corner (i.e. at an intersection of one vertical and one horizontal side wall of a foot), and this provides greater strength to the feet 20 to 23 and pallet 100 as a whole.

[0108] The foldable flaps 60 to 67 are located on the lower layer 30 such that, when folded, they provide an opening in the lower layer 30 configured to receive a wheel of a pallet lifting tyne.

[0109] Each of the upper liner layers 10, 11, the supporting layer 30, and the feet 20 to 23 are formed by the same type of sheeting, cut into substantially the same rectangular shape, when viewed in plan view; the edge flaps provide some additional length of the sheeting comprising the lower supporting layer 30, compared to each of the upper liner layers 10, 11, however each of the sheeting layers used in the pallet 100 have same width and thickness.

[0110] The sheeting for the liner layers, feet and lower layer comprises plastic fluted (patterned) sheeting, but could alternatively comprise conventional cardboard (e.g. corrugated cardboard), paperboard, fibreboard, CORFLUTE, honeycomb boards, or other fluted or non-fluted sheeting, and solid material sheeting including solid fibre boards.

[0111] With reference to FIG. 2, there is shown a lower supporting surface 30 where the flaps are market out and cut, but not in a folded position.

[0112] The central flaps 50, 51, 52 and 53 are located such that, in a folded position (see FIG. 1), they assist in the locating and holding in position the two middle feet 21 and 22.

[0113] There are four pairs of bi-folding flaps 60, 61, 62, 63, 64, 65, 66 and 67, which, together with the central flaps, 50 to 53, and the edge flaps 40, 45, locate and hold in position the four feet 20 to 23.

[0114] The flaps of lower layer 30 are configured to be located symmetrically on both sides of a central axis running along the length of the lower supporting layer 30 (i.e. with flaps 60 to 63 and 50, 51 on one side of the central length axis, and flaps 64 to 67, and 52, 53 on the other side of the central length axis). The flaps of lower layer 30 are also configured to be located symmetrically along both sides of a central axis running along the width of the lower layer 30 (i.e. through the point where the central flaps 50, 51 meet, and where the central flaps 52, 53 meet). However, the configuration of the flaps need not be symmetrical, and they may take a variety of different shapes. The principal purpose of the flaps is to assist in the locating and holding in place of the feet, and to strengthen the pallet 100.

[0115] The central flaps 50 to 53 and the bi-folding flaps 60 to 67 are located inwards from a perimeter 80 of the lower supporting layer 30. The inwardly located flaps are preferably configured to efficiently use material in the lower layer 30 that, depending on the pallet lifting device, may need to be cut out to enable wheels of the pallet lifting tynes to engage with the ground.

[0116] FIG. 3 depicts a front lower perspective view of the foot 22 of FIG. 1 (identical to the foot 23). Foot 22, like other feet 20, 21 and 23, comprises two vertical sides 22A, 22B and two horizontal sides 22C, 22D, and each side comprises at least two folded rectangular segments.

[0117] The first fold 29A in foot 22 is a back-fold that is folded in a first direction, and the subsequent folds 29B, 29C (only two of which are identified on the drawing by reference numerals) are folded in an opposing second direction.

[0118] The foot 22 in FIG. 3 is the result of the folding process of foot sheet 200, the initial steps of which are set out in FIGS. 4A to 4D. With reference to FIG. 4A, the sheet 200 for foot 22, like each of the respective sheets for feet 20, 21 and 23, comprises eleven foldable rectangular segments: 27A, 27B, 27C, 27D, 27E, 27F, 27G, 27H, 271, 27J, 27K. The segments are formed by folding along the ten crease lines 28A, 28B, 28C, 28D, 28E, 28F, 28G, 28H, 281, 28J.

[0119] The crease lines 28A to 28J in FIG. 4A are perpendicular (i.e. transverse) to the flute direction which is indicated by the flute lines extending along the length of the sheet 200. While the flute lines are shown in FIG. 4A (and FIG. 10), they are not shown in FIGS. 4B to 4D, and the sheeting in the remaining figures, for clarity of the drawings in a manner consistent with conventional patent drawing practice.

[0120] In FIG. 4A, the first rectangular segment, 27A, defined on one side by the left edge of the sheet and on an opposing side by crease line 28A, is back-folded in a first direction. In FIG. 4B, the second segment 27B, defined by crease lines 28A and 28B, is folded in a second direction (opposite to the first back-folding direction of the first segment). The remaining segments 27C to 27K in the sheet 200 are folded in the second direction, such as is depicted in folding of the third segment 27C and the fourth segment 27D, and so on, thereby forming the foot 22 depicted in FIG. 2.

[0121] The last segment 27K of foot, 22, is adhered by adhesive glue to the outside face of the segment 27G which it rests against in a fully folded (and formed) configuration. Each of the segments 27A, 27C, 27D, 27E, 27F, 27G, 27H, 271, 27J, and 27K (i.e. each segment except 27B) is adhered by adhesive glue to at least one adjacent vertical segment, as shown in FIG. 3. In other configurations, adhesive is not used on each of the segments of the sheeting.

[0122] With reference to FIG. 3, the back-folded segment, 27A, comprises an inner vertical wall on a first vertical side 22A of the foot 22. The second segment 27B, which is adjacent to the back-folded segment 27A, is a diagonal segment that extends diagonally between a lower portion on the first vertical side 22A of the foot 22 and a higher portion on an opposing second vertical side 22B of the foot 22.

[0123] The third segment, 27C, forms the innermost vertical wall on the second side 22B of the foot.

[0124] Each of the side walls 22A, 22B, 22C, 22D of foot 22 comprise at least two layers of folding rectangular segments. Vertical side walls 22A, 22B each have three layers of folding rectangular segments, and horizontal side walls 22C, 22D each have two layers of segments. Given the vertical load that a pallet bears, it is preferable that the number of layers in the vertical side walls of the feet is at least the same as, or greater than, the number of layers in the horizontal side walls of the feet.

[0125] In alternative configurations, the first segment may comprise the diagonal segment (i.e. there is no back-folded segment). While in some embodiments that configuration may be less robust than embodiments which include the back-folded segment, that configuration may be sufficiently robust for commercial purposes. In alternative configurations for the feet, such as those depicted in FIG. 10, there may be differing numbers of layers to each of the side walls, and the height and/or width of the foot may be modified to suit the pallet. In further configurations, the pallet feet may be greater in height as compared to width, or vice versa. The term rectangular is intended, as it is conventionally, to include a square shape but also other rectangles (i.e. the square is just a unique case of the class of shapes identified as rectangles). The foot comprising an elongate prism may alternatively comprise a variety of quadrilateral-based prisms (not just rectangle-based prisms), including trapezoid-based prisms and parallelogram-based prisms. One example would be an isosceles trapezoid-based prism, and in particular an isosceles trapezoid-based prism containing three adjacent isosceles triangle-based prisms.

[0126] FIGS. 5A to 5D depict a method of forming the pallet 100 of FIG. 1, the method including the steps of: forming four feet 20, 21, 22, 23 and forming a lower supporting layer 30, wherein the lower supporting layer includes fourteen (14) foldable flaps, 40, 45, 50 to 53, and 60 to 67 adapted to locate and hold the feet, 20 to 23, in position on the lower supporting layer 30 (see FIG. 5A); then joining the feet, 20 to 23, to the lower supporting layer 30 (see FIG. 5B); then folding the flaps upwardly and joining the foldable flaps to the feet (FIG. 5C); then forming a deck 13 comprising a plurality of upper liner layers 10,11 (FIG. 5D); and finally joining the deck 13 to the feet and to the foldable flaps (FIG. 5E). The joining is done by adhesive glue, however alternative adhering or joining means may be used as described above or as known to the skilled addressee.

[0127] With reference to FIGS. 5C and 5D in particular, eight of the folding flaps are bi-folding flaps 60 to 67, where the eight bi-folding flaps include first folds 70, 71 (only two of which are labelled with reference numerals) near a lower part of the feet 21, 23, respectively, and second folds 73, 74 (only two of which are labelled with reference numerals) near a top part of the feet 21, 23.

[0128] The eight bi-folding flaps, 60 to 67, each include a first section 75, 76 adapted to extend vertically and perpendicular to a horizontal plane of the lower layer 30, and a second section 78, 79 adapted to extend horizontally and parallel to the horizontal plane of the lower layer 30. Only two of the eight first sections and two of the second sections are labelled with reference numerals.

[0129] The first sections 75, 76 are joined to an outer side wall of the feet 21, 23, and the second sections 78, 79 are joined to the lowermost upper liner layer 11.

[0130] The foldable flaps, but more particularly the bi-folding flaps 60 to 67 are located on the lower layer 30 such that, when folded, they provide openings 85, 86, 87, 88 in the lower layer 30 configured to receive a wheel of a pallet lifting tyne (not shown). Continuing with reference to FIGS. 5C to 5E, the locations of the openings 85 to 88 are such that the tynes may enter the pallet from two sides of the pallet 100 (i.e. it is a 2-way pallet), and the wheels of the tynes will be received in the openings 85 to 88.

[0131] While not included in the embodiment of the pallet depicted in FIGS. 5A to 5D, a second supporting layer may be included such that a first supporting layer comprises the base layer and the second supporting layer (which may include foldable flaps that are configured to complement the foldable flaps of the first supporting layer) is underneath the one or more liner layers and in between the liner layers and the feet.

[0132] Referring to FIG. 5E, the pallet 100 includes four feet, 20 to 23, the internal diagonal segments 25B, 26B on a first side 91 of the pallet 100 extend upwardly from the lower layer of sheeting 30 and away from a central axis 93 of the pallet, in a first diagonal direction towards a first edge 91A of the pallet 100; and the internal diagonal segments 27B, 29B on a second side 92 of the pallet extend upwardly from the lower layer 30 of sheeting away from the central axis 92 of the pallet, in a second direction opposing the first diagonal direction, towards a second edge 92A.

[0133] The first segment of each of the four feet (only one of which is labelled, 27A) extend vertically and form the interior wall of each respective foot. This configuration further operates to increase the vertical strength of the feet 20 to 23, and to reduce the likelihood of the feet failing due to the dynamic load of the pallet during use.

[0134] FIGS. 6 and 7 depict pallets 300 and 400 with two and three feet, respectively. The number, type and configuration of the flaps is adapted to match the location of the feet in those arrangements, but otherwise the pallets 300, 400 are substantially the same as the pallet 100 described with reference to FIGS. 1 to 5. The horizontal sections of the bi-folding flaps (not shown) for pallets 300, 400 may be extended in these configurations, in order to provide appropriate sizing and location of the openings (also not shown) in the supporting layer 330, 430 for receiving tyne wheels.

[0135] FIG. 8 depicts four different configurations for the feet of the invention, each of which, and any combination of which, may be used in the pallet of the invention. Foot 120 has a diagonal segment 127A comprising an edge segment (the first segment) of the sheet used to form foot 120. Foot 120 has a total of 10 segments, and does not include any back-fold.

[0136] Foot 220 has a back-folded diagonal segment 227B, only one layer in each of the upper and lower walls, and two layers in each of the left and right side walls; it is formed from a sheet comprising seven rectangular segments. Foot 320 is the same as foot 20, rotated 180 degrees around a central axis running along the length of the foot. Foot 420 has thicker walls than the other feet, including three layers on each of the upper and lower walls and four layers on each of the left and right side walls. Foot 420 comprises 15 segments and diagonal segment 427B is a back-folded second segment.

[0137] FIG. 9 depicts a foot 520 that is different to the feet shown in FIG. 8. Foot 520 is configured such that each of its walls have the same number of layers (three). It is formed by a different folding arrangement where folding requires coordinating the arrangement of the segments during the formation process, as opposed the more elaborate method of performing an initial back-fold then sequential folding in an opposing direction (or, more simply, just folding all segments in the same direction, like foot 120). The edge segments of the sheet used to form foot 520 are located on the upper and lower sides. The diagonal segment 527G comprises the middle (seventh) segment of the 13 segment sheet that is folded to form foot 520.

[0138] For the feet depicted in FIGS. 8 and 9, they each comprise folded rectangular segments and form a rectangular prism. With the exception of foot 120, each of the feet (i.e. feet 220, 320, 420 and 520) have folding rectangular segments that comprise a back-folded segment folded in a first direction, and an adjacent segment folded in an opposing second direction.

[0139] FIG. 10 depicts a pallet 600 made of fluted sheeting: the four feet 620, 621, 622, 633, the deck 613 (comprising two upper liner layers) and lower layer 630 are each formed from the same type of flued sheeting, namely CORFLUTE. The fluted sheeting includes corrugations in the flute (not shown, but the flute direction is visible by the lines 628A, 628B which appear on the surface of the sheeting (only two lines are indicated with a reference numeral). The corrugations in the two upper liner layers are offset, so that the corrugations in the first upper liner layer are offset from those in the second upper liner layer (this is not visible in FIG. 10 due to the upper liner layers being adhered together). This offset arrangement of the corrugations assists to strengthen the deck, or reduce the likelihood of structural failure of the deck.

[0140] In addition to the openings 685, 686, 687, 688 for receiving the wheels of tynes additional openings 684, 689, are formed by folding the central foldable flaps, of pallet 600, only two of which flaps, 650, 652 are visible in FIG. 10).

[0141] FIGS. 11A and 11B depict a racking pallet 700, that is able to be racked (i.e. stored on a single or multi-level rack, to support high stacking of single items or palletised loads).

[0142] Pallet 700 is substantially the same as the pallet 100 of FIG. 1, however it includes racking strips 790, each of which comprise two sheeting strip layers, that are joined together and joined to the lower supporting layer 730 in the assembled pallet 700. The racking strips 790 run transverse to the direction of the pallet feet 720 (just one of which is labelled on FIGS. 11A and 11B), and on both sides of the openings formed by folding the foldable flaps 750 (just one of which is labelled on FIGS. 11A and 11B).

[0143] FIG. 11B depicts the principal components of the pallet 700, vertically separated from each other. The components include the upper liner layers comprising the deck 713, the feet 720, and the lower supporting layer 730, with its flaps 750 folded outwards. The location of the racking strips 790 relative to the openings formed by the foldable flaps 750 is more clearly visible in FIG. 11B.

[0144] FIGS. 12A and 12B depict a 4-way entry pallet 800, which includes openings 895 on all four sides (openings on only two sides are visible in FIG. 12A) to allow the tynes of a forklift to enter on all four sides.

[0145] Pallet 800 is substantially the same as the pallet 100 of FIG. 1, however it includes twelve (12) shorter feet segments 820, instead of the four (4) longer feet that span the length of the pallet 100. Another difference between the pallet 100 of FIG. 1 and the pallet 800, is that there are only 6 foldable flaps 850, and these are all located on the edges of the lower supporting layer 830 of the pallet 800, and constitute two opposing side walls of the pallet 800. For diagrammatic simplicity, only two of the feet 820 are labelled with reference numerals, and only two of the foldable edge flaps 850 is labelled with reference numerals.

[0146] FIG. 12B depicts the principal components of the 4-way pallet 800, vertically separated from each other. The components include the two cross flute laminated upper liner layers comprising the deck 813, the twelve feet 820, and the lower supporting layer 830, with its openings and flaps 850 folded upwards.

[0147] In the 4-way pallet embodiment 800 depicted in FIGS. 12A and 12B, the deck 813 comprises two upper liner layers, each comprising a 10 mm thick extruded sheet, where the two liner layers have transverse flute directions (i.e. are cross-fluted). The base or lower supporting layer 830 comprises a heavy duty 5 mm thick fluted sheet.

[0148] In relation to each of the pallets 100, 300, 400, 600, 700, 800 depicted in the Figures, they comprise the standard dimensions for the Australian domestic market (1165 W1165 L90 160 H). However, the dimensions of the pallet may vary to suit standard pallet sizes in other locations or contexts, such as Australian export (1150 W1150 L90-160 H), Asia (1100 W1100 L90-160 H), North and South America (1016 W1219 L90-160 H, or 1016 L1219 W90-160 H), Europe, UK (800 W1200 L90-160 H, or 800 L1200 W90-160 H), or custom dimensions to suit particular contexts or manufacturers. All of the preceding measurements for the length (L), width (W) and height (H) of the pallets are in millimeters.

[0149] Benefits of the invention are manifold. In particular, the pallets of the invention are strong and simple to manufacture due to one or more of the improved design features, including: [0150] The supporting lower layer operates to bolster the feet and provide the pallet greater resistance to structural failure, as well as to securely locate the feet in place; [0151] The back-fold operates to strengthen the internal structure of each foot; [0152] A plurality of feet are arranged to spread the pallet load; [0153] A plurality of feet have their diagonal segments in a mutually reinforcing orientation; [0154] The flap location coincides with the location of wheels in lifting tynes, to minimise the material required to form the pallet; [0155] Cross-fluting of layers provides strength to the pallet; [0156] The manufacture is simplified due to each element of pallet being capable of being manufactured from the same type of sheeting (compare with other cardboard pallets, which, for example, include a combination of circular supporting feet and sheeting on honeycomb board); and/or [0157] Manufacturing is simplified as all components may be assembled using only adhesive or simple joining means.

Interpretation

[0158] Reference throughout this specification to one embodiment or an embodiment means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases in one embodiment or in an embodiment in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.

[0159] Similarly it should be appreciated that in the above description of example embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description of Specific Embodiments are hereby expressly incorporated into this Detailed Description of Specific Embodiments, with each claim standing on its own as a separate embodiment of this invention.

[0160] Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.

[0161] As used herein in the specification and claims, including as used in the examples and unless otherwise expressly specified, all numbers may be read as if prefaced by the word about or approximately, even if the term does not expressly appear. The phrase about or approximately may be used when describing magnitude and/or position to indicate that the value and/or position described is within a reasonable expected range of values and/or positions. For example, a numeric value may have a value that is +/0.1% of the stated value (or range of values), +/1% of the stated value (or range of values), +/2% of the stated value (or range of values), +/5% of the stated value (or range of values), +/10% of the stated value (or range of values), etc. Any numerical values given herein should also be understood to include about or approximately that value, unless the context indicates otherwise. For example, if the value 10 is disclosed, then about 10 is also disclosed. Any numerical range recited herein is intended to include all sub-ranges subsumed therein. It is also understood that when a value is disclosed that less than or equal to the value, greater than or equal to the value and possible ranges between values are also disclosed, as appropriately understood by the skilled artisan. For example, if the value X is disclosed the less than or equal to X as well as greater than or equal to X (e.g., where X is a numerical value) is also disclosed. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

Different Instances of Objects

[0162] As used herein, unless otherwise specified the use of the ordinal adjectives first, second, third, etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

Specific Details

[0163] In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

Terminology

[0164] The term fluted sheeting is intended to comprise any sheeting including a fluted layer and one or more liner layers. Fluted sheeting therefore encompasses a wide range of sheeting including conventional fibreboard, CORFLUTE, honeycomb boards, or other fluted sheeting.

[0165] The flute direction in a corrugated sheet may be understood as the width of the sheet (or the width across the corrugator machine).

[0166] The term sheeting is intended to comprise fluted and non-fluted sheeting (e.g. solid fibre board, or paperboard).

[0167] In describing the preferred embodiment of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as forward, rearward, radially, peripherally. upwardly, downwardly, and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms, unless the context requires otherwise.

[0168] The terms a and an mean one or more, unless expressly specified otherwise

[0169] Neither the title nor any abstract of the present application should be taken as limiting in any way the scope of the claimed invention.

[0170] Where the preamble of a claim recites a purpose, benefit or possible use of the claimed invention, it does not limit the claimed invention to having only that purpose, benefit or possible use.

[0171] In the present specification, terms such as part, component, means, section, or segment may refer to singular or plural items and are terms intended to refer to a set of properties, functions or characteristics performed by one or more items having one or more parts. It is envisaged that where a part, component, means, section, segment, or similar term is described as consisting of a single item, then a functionally equivalent object consisting of multiple items is considered to fall within the scope of the term; and similarly, where a part, component, means, section, segment, or similar term is described as consisting of multiple items, a functionally equivalent object consisting of a single item is considered to fall within the scope of the term. The intended interpretation of such terms described in this paragraph should apply unless the contrary is expressly stated or the context requires otherwise.

[0172] As used herein in the specification and claims, including as used in the examples and unless otherwise expressly specified, all numbers may be read as if prefaced by the word about or approximately, even if the term does not expressly appear. The phrase about or approximately may be used when describing magnitude and/or position to indicate that the value and/or position described is within a reasonable expected range of values and/or positions. For example, a numeric value may have a value that is +/0.1% of the stated value (or range of values), +/1% of the stated value (or range of values), +/2% of the stated value (or range of values), +/5% of the stated value (or range of values), +/10% of the stated value (or range of values), etc. Any numerical values given herein should also be understood to include about or approximately that value, unless the context indicates otherwise. For example, if the value 10 is disclosed, then about 10 is also disclosed. Any numerical range recited herein is intended to include all sub-ranges subsumed therein. It is also understood that when a value is disclosed that less than or equal to the value, greater than or equal to the value and possible ranges between values are also disclosed, as appropriately understood by the skilled artisan. For example, if the value X is disclosed the less than or equal to X as well as greater than or equal to X (e.g., where X is a numerical value) is also disclosed. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

[0173] The term connected or a similar term, should not be interpreted as being limitative to direct connections only. Thus, the scope of the expression an item A connected to an item B should not be limited to items or systems wherein an output of item A is directly connected to an input of item B. It means that there exists a path between an output of A and an input of B which may be a path including other items or means. Connected, or a similar term, may mean that two or more elements are either in direct physical or electrical contact, or that two or more elements are not in direct contact with each other yet still co-operate or interact with each other.

Comprising and Including

[0174] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word comprise or variations such as comprises or comprising are used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

[0175] Any one of the terms: including or which includes or that includes as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others. Thus, including is synonymous with and means comprising.

Scope of Invention

[0176] Thus, while there has been described what are believed to be the preferred embodiments of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as fall within the scope of the invention. For example, any formulas given above are merely representative of procedures that may be used.

[0177] Functionality may be added or deleted from the block diagrams and operations may be interchanged among functional blocks. Steps may be added or deleted to methods described within the scope of the present invention.

[0178] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.