Cardboard pallet

Abstract

Methods, devices, and systems for assembling a pallet are provided. In particular, a pallet is provided that is made from multiple pieces that are bent from an initial planar shape to a final shape. In some embodiments, a transverse piece locks at least one longitudinal piece in the final shape without the use of fasteners or adhesives. The resulting pallet can be loaded with materials and then maneuvered and transported using a forklift. In addition, the pieces can be made from cardboard which significantly reduces the weight of the pallet.

What is claimed is: 
     
         1 . A pallet assembly, comprising:
 a first longitudinal piece and a second longitudinal piece, each longitudinal piece having:
 a plurality of bend lines, wherein each longitudinal piece is configured to bend along the plurality of bend lines from an initial shape to a final shape, 
 at least one horizontal portion defined between two bend lines of the plurality of bend lines, 
 at least one vertical portion defined between two bend lines of the plurality of bend lines, 
 at least one transverse slot; and 
   a transverse piece selectively connected to the at least one transverse slot of each longitudinal piece to secure each longitudinal piece in the final shape, wherein at least a portion of the transverse piece is perpendicular to the at least one horizontal portion and the at least one vertical portion of each longitudinal piece when each longitudinal piece is in the final shape.   
     
     
         2 . The pallet assembly of  claim 1 , wherein the at least one transverse slot of the longitudinal pieces extends substantially perpendicular to the plurality of bend lines. 
     
     
         3 . The pallet assembly of  claim 1 , wherein the at least one transverse slot of the longitudinal pieces extends substantially parallel to the plurality of bend lines. 
     
     
         4 . The pallet assembly of  claim 1 , further comprising:
 a planar piece having a first end selectively connected to a planar slot in at least one of the first longitudinal piece and the second longitudinal piece, and the planar piece having a second end selectively connected to an additional planar slot in at least one of the first longitudinal piece and the second longitudinal piece, wherein the planar piece has a horizontal portion that is substantially parallel with the at least one horizontal portion of each longitudinal piece.   
     
     
         5 . The pallet assembly of  claim 1 , wherein the transverse piece has at least one bend line, and the transverse piece is configured to bend along the at least one bend line from an initial shape to a final shape, and wherein the transverse piece is bent to the final shape prior to being selectively connected to the at least one transverse slot of each longitudinal piece. 
     
     
         6 . The pallet assembly of  claim 1 , wherein the at least one transverse slot of each longitudinal piece extends across at least one bend line of the plurality of bend lines of each longitudinal piece. 
     
     
         7 . The pallet assembly of  claim 1 , wherein each longitudinal piece is substantially planar in the initial shape. 
     
     
         8 . The pallet assembly of  claim 1 , wherein each longitudinal piece and the transverse piece are made from a double-wall, kraft cardboard having a flute BC and an edge crush test of 42 pounds/inch. 
     
     
         9 . A method of assembling a pallet, comprising:
 bending a first longitudinal piece along a plurality of first bend lines from an initial shape to a final shape, wherein at least one horizontal portion is defined between two bend lines of the plurality of first bend lines, wherein at least one vertical portion is defined between two bend lines of the plurality of first bend lines, and wherein the first longitudinal piece has at least one transverse slot;   bending a second longitudinal piece along a plurality of second bend lines from an initial shape to a final shape, wherein at least one horizontal portion is defined between two bend lines of the plurality of second bend lines, wherein at least one vertical portion is defined between two bend lines of the plurality of second bend lines, and wherein the second longitudinal piece has at least one transverse slot;   positioning the first and second longitudinal pieces adjacent to each other such that a vertical portion of the at least one vertical portion of the first longitudinal piece is adjacent to a vertical portion of the at least one vertical portion of the second longitudinal piece; and   positioning a transverse piece in the at least one transverse slot of each longitudinal piece to secure each longitudinal piece in the final shape, wherein at least a portion of the transverse piece is perpendicular to the at least one horizontal portion and the at least one vertical portion of each longitudinal piece.   
     
     
         10 . The method of  claim 9 , further comprising:
 bending a third longitudinal piece along a plurality of third bend lines from an initial shape to a final shape, wherein at least one horizontal portion is defined between two bend lines of the plurality of third bend lines, wherein at least one vertical portion is defined between two bend lines of the plurality of third bend lines, and wherein the third longitudinal piece has at least one transverse slot;   positioning the third longitudinal piece adjacent to the first and second longitudinal pieces such that a vertical portion of the third longitudinal piece is adjacent to the vertical portions of the first and second longitudinal pieces; and   positioning the transverse piece in the at least one transverse slot of the third longitudinal piece to secure the third longitudinal piece in the final shape, wherein at least a portion of the transverse piece is perpendicular to the at least one horizontal portion and the at least one vertical portion of the third longitudinal piece   
     
     
         11 . The method of  claim 9 , further comprising:
 bending a planar piece along a plurality of planar bend lines from an initial shape to a final shape, wherein at least one horizontal portion is defined between two bend lines of the plurality of planar bend lines;   positioning a first end of the planar piece in a planar slot of at least one of the first longitudinal piece and the second longitudinal piece; and   positioning a second end of the planar piece in an additional planar slot of at least one of the first longitudinal piece and the second longitudinal piece.   
     
     
         12 . The method of  claim 9 , further comprising:
 positioning a second transverse piece in the at least one transverse slot of each longitudinal piece to secure each longitudinal piece in the final shape, wherein at least a portion of the second transverse piece is perpendicular to the at least one horizontal portion and the at least one vertical portion of each longitudinal piece   
     
     
         13 . The method of  claim 9 , further comprising:
 bending the transverse piece along at least one bend line from an initial shape to a final shape, and wherein the transverse piece is bent to the final shape prior to positioning in the at least one transverse slot of each longitudinal piece.   
     
     
         14 . A pallet system, comprising:
 a longitudinal piece having:
 a plurality of bend lines, wherein the longitudinal piece is configured to bend along the plurality of bend lines from an initial shape to a final shape, 
 at least one horizontal portion defined between two bend lines of the plurality of bend lines, 
 at least one vertical portion defined between two bend lines of the plurality of bend lines, 
 at least one transverse slot, 
 at least one fork slot configured to form at least a portion of a fork aperture; and 
   a transverse piece having at least one recess, wherein the transverse piece selectively connects to the longitudinal piece at the at least one transverse slot to secure the longitudinal piece in the final shape, and the at least one recess engages the at least one vertical portion of the longitudinal piece, wherein at least a portion of the transverse piece is perpendicular to the at least one horizontal portion and the at least one vertical portion of the longitudinal piece.   
     
     
         15 . The pallet system of  claim 14 , wherein the at least one fork slot is at least partially positioned on a vertical portion of the at least one vertical portion. 
     
     
         16 . The pallet system of  claim 15 , wherein the at least one fork slot extends across at least one bend line of the plurality of bend lines. 
     
     
         17 . The pallet system of  claim 14 , wherein the longitudinal piece at least partially defines four fork apertures, wherein a first fork aperture and a second fork aperture of the four fork apertures are substantially parallel to each other. 
     
     
         18 . The pallet system of  claim 17 , wherein a third fork aperture and a fourth fork aperture are substantially parallel to each other, and wherein the first and second fork apertures intersect the third and fourth fork apertures. 
     
     
         19 . The pallet system of  claim 14 , wherein the transverse piece has at least one bend line, and the transverse piece is configured to bend along the at least one bend line from an initial shape to a final shape, and wherein the transverse piece is bent to the final shape prior to being selectively connected to the at least one transverse slot of the longitudinal piece. 
     
     
         20 . The pallet system of  claim 14 , further comprising:
 a planar piece having a first end selectively connected to a planar slot in the longitudinal piece, and the planar piece having a second end selectively connected to an additional planar slot in the longitudinal piece, wherein the planar piece has a horizontal portion that is substantially parallel with the at least one horizontal portion of each longitudinal piece.