Pallet and Methods for Making Same

Abstract

A pallet includes a platform having a first side for carrying an object thereon and a second side opposite the first side, and a first elongate rectangular leg member positioned on the second side of the platform proximate a first end of the platform, and a second elongate rectangular leg member positioned on the second side of the platform proximate a second end of the platform opposite the first end. The platform and the leg members can be integrally formed from a single sheet of material, such as corrugated paper. The legs can include openings for receiving support members, such as paper cones or paper tubes.

1 . A method for making a pallet comprising the steps of:
 (a) providing a blank sheet of material having a first plurality of fold lines proximate a first end of the blank and a second plurality of fold lines proximate a second end opposite the first end of the blank; and   (b) folding the blank along the first plurality of fold lines to form a first leg member proximate the first end of the blank, and along the second plurality of fold lines to form a second leg member proximate the second end of the blank, whereby a remaining portion of the blank defines a platform supported by the first and second leg members.   
   
   
       2 . A method according to  claim 1 , wherein the blank sheet of material comprises paper. 
   
   
       3 . A method according to  claim 1 , wherein each of the first and second pluralities of fold lines comprise substantially parallel first, second, third and fourth fold lines, and each of the first and second leg members comprise an elongate rectangular member for supporting the platform above a surface. 
   
   
       4 . A method according to  claim 3 , further comprising the step of adhering an area intermediate the first end of the blank and the first fold line of the first plurality of fold lines to an area of the blank intermediate the fourth fold line of the first plurality of fold lines and the first fold line of the second plurality of fold lines. 
   
   
       5 . A method according to  claim 3 , further comprising the steps of:
 (a) forming a first opening intermediate the first end of the blank and the first fold line of the first plurality of fold lines; and   (b) forming a second opening intermediate the second and third fold lines of the first plurality of fold lines and positioned whereby the first and second openings are axially aligned when the blank is folded along first, second, third and fourth fold lines of the first plurality of fold lines.   
   
   
       6 . A method according to  claim 5 , further comprising the step of positioning a support member within the aligned first and second openings for strengthening the first leg member. 
   
   
       7 . A method according to  claim 6 , wherein the support member comprises at least one selected from the group consisting of a paper cone and a paper tube. 
   
   
       8 . A method according to  claim 3 , further comprising the steps of:
 (a) forming a first opening intermediate the first and second fold lines of the first plurality of fold lines of the blank,   (b) forming a second opening intermediate the third and fourth fold lines of the first plurality of fold lines of the blank;   (c) forming a third opening intermediate the first and second fold lines of the second plurality of fold lines of the blank;   (d) forming a fourth opening intermediate the third and fourth fold lines of the second fold lines of the blank; and   (e) wherein the first, second, third and fourth openings are axially aligned when the blank is folded along the first and second pluralities of fold lines whereby the first and second leg members define an area for receiving at least one fork of a forklift.   
   
   
       9 . A method according to  claim 8 , further comprising the step of forming perforated sections proximate the first, second, third and fourth openings of the blank whereby the perforated sections are separable from the blank to enlarge the first, second, third and fourth openings. 
   
   
       10 . A method according to  claim 1 , further comprising the step of attaching a third leg member positioned on the platform intermediate the first and second leg members. 
   
   
       11 . A method according to  claim 1 , wherein the first and second pluralities of fold lines each comprise substantially parallel first, second, third, fourth, fifth and sixth fold lines, and each of the first and second leg members comprise an elongate rectangular member for supporting the platform above a surface, and further wherein the platform includes a first wing section extending outwardly from the first leg member and a second wing section extending outwardly from the second leg member. 
   
   
       12 . A method according to  claim 1 , further comprising the step of mounting the first and second leg members on a substantially flat base member for positioning on a surface, and wherein the base member includes at least one opening for receiving a pallet jack. 
   
   
       13 . A pallet made according to the method of  claim 1 . 
   
   
       14 . A pallet comprising:
 (a) a platform having a first side for carrying an object thereon and a second side opposite the first side; and   (b) a first elongate rectangular leg member positioned on the second side of the platform proximate a first end of the platform, and a second elongate rectangular leg member positioned on the second side of the platform proximate a second end of the platform opposite the first end.   
   
   
       15 . A pallet according to  claim 14 , wherein the platform and the first and second leg members are integrally formed from a single sheet of paper. 
   
   
       16 . A pallet according to  claim 15 , wherein the first leg member comprises at least four walls formed by making at least four folds proximate a first end of the sheet of paper, and the second leg member comprises at least four walls formed by making at least four folds proximate a second end of the sheet of paper opposite the first end. 
   
   
       17 . A pallet according to  claim 14 , wherein the first leg member is coextensive with the first end of the platform, and the second leg member is coextensive with the second end of the platform. 
   
   
       18 . A pallet according to  claim 14 , further comprising a third elongate rectangular leg member mounted on the second side of the platform at a position intermediate the first and second leg members, wherein the first, second and third leg members are substantially parallel. 
   
   
       19 . A pallet according to  claim 14 , further comprising a substantially flat base member attached to the first and second leg members for positioning on a surface, and wherein the base member includes at least one opening for inserting a pallet jack therethrough. 
   
   
       20 . A pallet according to  claim 14 , wherein the pallet is comprised of corrugated paper, and further wherein the platform and the first and second leg members are corrugated in a first direction, and the base member is corrugated in a second direction opposite the first direction. 
   
   
       21 . A pallet according to  claim 14 , further comprising a plurality of support members positioned in the first and second leg members in substantially perpendicular relation to the platform. 
   
   
       22 . A pallet according to  claim 14 , wherein the first leg member includes a first opening, and the second leg member includes a second opening aligned with the first opening on an axis substantially parallel with the platform whereby at least one fork of a fork lift can be positioned within the first and second openings. 
   
   
       23 . A pallet according to  claim 14 , wherein each of the first and second leg members includes:
 (a) a first wall attached and parallel to the platform;   (b) a second wall extending perpendicularly from the first wall;   (c) a third wall extending perpendicularly from the second wall and parallel to the platform for supporting the platform on a surface; and   (d) a fourth wall extending perpendicularly from the third wall and connecting the third wall to the platform.   
   
   
       24 . A pallet according to  claim 23 , wherein the second and fourth walls of the first and second leg members each include a flap section that is at least partially removable to define an opening for receiving at least one fork of a fork lift. 
   
   
       25 . A pallet according to  claim 14 , wherein the platform includes a first wing section extending outwardly from the first leg member, and a second wing section extending outwardly from the second leg member.