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.

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.