Disposable/recyclable pallet and method

Abstract

A pallet for supporting a load of packages is disclosed. The pallet includes a support structure comprising flexible film wrapped around at least one of the layers of the load. The flexible film is wrapped around two axes which are generally perpendicular to one another and preferably located within the same plane such that the flexible film covers at least a majority of the layer(s). The pallet also includes a base adhered to the flexible film which is adapted to receive forks of a forklift. The base may be constructed from multiple pieces of a disposable/recyclable material such as plastic foam (a.k.a. Styrofoam).

We claim:  
     
         1 . A pallet for supporting a load of packages comprising multiple layers, said pallet comprising: 
 a) a support structure comprising flexible film wrapped around at least one of said multiple layers around a first axis and a second axis, said first axis being generally perpendicular to said second axis, whereby said flexible film covers at least a majority of said at least one of said multiple layers; and    b) a base adhered to said flexible film which is adapted to receive forks of a forklift.    
     
     
         2 . The pallet of  claim 1  wherein said at least one of said multiple layers is the lowermost layer of said load.  
     
     
         3 . The pallet of  claim 1  wherein said first axis and said second axis are located on the same plane.  
     
     
         4 . The pallet of  claim 1  wherein said flexible film and said base are constructed from disposable/recyclable materials.  
     
     
         5 . The pallet of  claim 1  wherein said base is comprised of multiple pieces of lightweight material.  
     
     
         6 . The pallet of  claim 5  wherein said lightweight material is plastic foam.  
     
     
         7 . The pallet of  claim 1  wherein the total surface area of said base is between about 25 and 40% of the total surface area of a bottom surface of said at least one of said multiple layers.  
     
     
         8 . A method for producing a pallet for supporting a load of packages comprising multiple layers, said method comprising: 
 a) wrapping at least one of said multiple layers with a flexible film around a first axis;    b) wrapping said at least one of said multiple layers with a flexible film around a second axis which is generally perpendicular to said first axis;    c) adhering a base to said flexible film.    
     
     
         9 . The method of  claim 7  wherein said at least one of said multiple layers is the lowermost layer of said load.  
     
     
         10 . The method of  claim 7  wherein said first axis and said second axis are located on the same plane.  
     
     
         11 . The method of  claim 7  wherein the step of adhering a base to said flexible film comprises: 
 a) providing at least one plastic foam piece which is not fully cured;  
 b) pressing said at least one plastic foam piece onto said flexible film; and  
 c) allowing said at least one plastic foam pieces to fully cure, thereby causing said at least one plastic foam piece to adhere to said flexible film.  
 
     
     
         12 . The method of  claim 7  wherein the step of adhering a base to said flexible film comprises: 
 a) providing at least one plastic foam piece having a first surface;  
 b) heating said first surface of said at least one plastic foam piece so that said first surface is tacky;  
 c) pressing said first surface of said at least one plastic foam piece onto said flexible film; and  
 d) allowing said first surface of said at least one plastic foam piece to cool down, thereby causing said at least one plastic foam piece to adhere to said flexible film.  
 
     
     
         13 . A pallet for supporting a load of packages comprising multiple layers, said pallet comprising: 
 a) support means for supporting said load of packages, said support means comprising flexible film wrapped around at least one of said multiple layers around a first axis and a second axis, said first axis being generally perpendicular to said second axis, whereby said flexible film covers at least a majority of said at least one of said multiple layers; and    b) base means adhered to said support means for receiving forks of a forklift.