Economical and ecological pallet material and method for making the same

Abstract

A low-cost, strong, and ecological pallet is constructed with pallet blocks having honeycomb cores. The honeycomb cores provide strength in the vertical direction, and their integrity is protected by a honeycomb material overwrap. The honeycomb material wrap provides exceptional strength against lateral forces. The pallet and pallet blocks may be manufactured of kraft material or other sturdy materials.

What is claimed is:  
     
         1 . A block comprising: 
 a honeycomb core having a rectangular cross-section; and    a honeycomb overwrap attached to said honeycomb core along at least one side of said rectangular cross-section.    
     
     
         2 . The block of  claim 1  wherein said honeycomb core and said honeycomb overwrap are comprised of kraft material.  
     
     
         3 . The block of  claim 1  wherein said honeycomb overwrap is attached to said honeycomb core along four sides of said rectangular cross-section.  
     
     
         4 . The block of  claim 1  wherein said honeycomb core comprises a first honeycomb layer and a second honeycomb layer.  
     
     
         5 . A pallet comprising: 
 a pallet deck; and    a honeycomb support attached to said honeycomb pallet deck, wherein said honeycomb support includes a honeycomb core having a rectangular cross-section and an overwrap attached to said honeycomb core along at least two sides of said rectangular cross-section.    
     
     
         6 . The pallet of  claim 5 , wherein said honeycomb support is a plurality of support blocks arranged on said pallet deck to allow four-way entry underneath said pallet deck.  
     
     
         7 . The pallet of  claim 5 , wherein said honeycomb support is a plurality of support runners, extending across a width of said pallet deck.  
     
     
         8 . The pallet of  claim 7 , wherein said core is comprised of a first honeycomb layer and a second honeycomb layer.  
     
     
         9 . The pallet of  claim 7 , wherein said overwrap comprises a honeycomb overwrap.  
     
     
         10 . The pallet of  claim 7 , wherein said overwrap comprises a corrugated overwrap.  
     
     
         11 . The pallet of  claim 5 , wherein said support comprises a plurality of runners and a plurality of support blocks, at least one of said support blocks being attached to each of said plurality of runners.  
     
     
         12 . The pallet of  claim 11 , wherein said support blocks are attached to said runners by said overwrap.  
     
     
         13 . The pallet of  claim 12 , wherein said overwrap is a corrugated overwrap.  
     
     
         14 . The pallet of  claim 13 , wherein said overwrap is a honeycomb overwrap.  
     
     
         15 . The pallet of  claim 5 , further comprising a bottom sheet attached to said honeycomb support.  
     
     
         16 . A runner comprising: 
 a honeycomb core having a rectangular cross-section, a first honeycomb layer and a second honeycomb layer; and    a honeycomb overwrap attached to said honeycomb core along at least two sides of said rectangular cross-section    
     
     
         17 . The runner of  claim 16  wherein said honeycomb core and said honeycomb overwrap comprise kraft material.  
     
     
         18 . The runner of  claim 16  wherein said honeycomb overwrap is attached to said honeycomb core along four sides of said rectangular cross-section.  
     
     
         19 . A method for manufacturing a pallet comprising: 
 providing a pallet deck;    providing a honeycomb core;    providing an overwrap;    attaching said overwrap to at least two sides of said honeycomb core to create a honeycomb support; and    attaching said honeycomb support to said honeycomb pallet deck.    
     
     
         20 . The method of  claim 19 , wherein said step of providing a honeycomb core comprises: 
 providing a first honeycomb layer; and    providing a second honeycomb layer.    
     
     
         21 . The method of  claim 19 , wherein said step of providing an overwrap comprises: 
 providing a honeycomb overwrap; and    providing a corner structure in said honeycomb overwrap, said corner structure enabling said honeycomb overwrap to fold along desired lines.    
     
     
         22 . The method of  claim 21 , wherein said step of providing a corner structure comprises cutting a portion of said overwrap in a V-shape.  
     
     
         23 . The method of  claim 22 , wherein said step of providing a corner structure comprises crushing a portion of said overwrap.  
     
     
         24 . The method of  claim 19 , wherein said step of providing an overwrap comprises providing a corrugated overwrap.  
     
     
         25 . The method of  claim 19 , wherein said step of providing a honeycomb core comprises providing a single honeycomb layer runner and attaching to said single honeycomb layer runner a plurality of honeycomb blocks, wherein said single honeycomb layer runner extends across an entire width of said honeycomb pallet deck and said plurality of honeycomb blocks are shorter than the single honeycomb layer runner.  
     
     
         26 . The method of  claim 19 , further comprising providing a bottom sheet and attaching said bottom sheet to said honeycomb support.  
     
     
         27 . A support comprising: 
 a honeycomb runner having a rectangular cross-section;    a plurality of honeycomb pallet blocks attached to said honeycomb runner; and    a honeycomb overwrap wrapped around said honeycomb runner and said plurality of honeycomb pallet blocks.