Paperboard runners and paperboard pallets constructed therewith

Abstract

Broadly, the present invention is directed to paperboard runners and paperboard pallets constructed therewith. One aspect of the invention comprises a paperboard pallet comprising an upper deck and a lower deck having a plurality of runners interposed therebetween and affixed to each of said decks. Each of the runners comprises a sheet of paperboard that has been folded into a rectangular form having top and bottom walls, a pair of sidewalls, and a central vertical wall (e.g., the two ends of the sheet pressed together) interposed between the sidewalls. The top wall has openings. The central wall has quarter-round cut-outs located at the longitudinal ends of the top wall cut-out areas. The top wall openings are adapted to receive flaps having central slots cut in them. The flaps are selected from: flaps formed from said runner top wall; flaps cut from an upper deck attached to said runner; or flaps formed from a rectangular insert which has a pair of end slotted flaps, which insert fits into said top wall opening with said end slotted flaps folding downwardly into said quarter-round cut-outs. Another aspect of the present invention comprises the runners described herein. A further aspect of the present invention is an alternate paperboard runner which comprises a sheet of paperboard that has been folded into a rectangular form by one end being folded to form a first bottom wall, a first sidewall, a first top wall, and a second sidewall; and the other end being folded into an "S" configuration to form a central vertical wall, a part second top wall which lays against said first top wall, and a part second bottom wall which lays against said first bottom wall. The top wall has openings. The central vertical wall has quarter-round cut-outs located at the longitudinal ends of said top wall cutout areas. The top wall openings are adapted to receive flaps which have central slots cut in them. The flaps are selected from: flaps formed from said runner top wall; flaps cut from an upper deck attached to said runner; or flaps formed from a rectangular insert which has a pair of end slotted flaps which insert fits into said top wall opening with said end slotted flaps folding downwardly into said quarter round cut-outs. This paperboard pallet embodiment can be made collapsible for shipment and storage, yet it can be simple and quickly assembled into a strong, lightweight, disposable pallet.

We claim: 
     
       1. A paperboard blank having an outer periphery defining a width and a longitudinal extent and configured for foldable assembly into a runner having a top wall with at least one opening of a given width and longitudinal extent, a pair of parallel side walls perpendicular to said top wall, a bottom wall parallel to said top wall, a central wall parallel to and intermediate said side walls, and at least two flaps disposed perpendicular to said central wall at opposite longitudinal ends of said top wall opening and having central slots configured for retaining said central wall therewithin, said flaps selected from (a) flaps .[.provided with.]. .Iadd.formed from .Iaddend.said runner top wall, (b) flaps provided with an upper deck attached to said runner, (c) flaps provided with .[.a rectangular.]. .Iadd.an .Iaddend.insert which has a pair of end slotted flaps which insert fits into said top wall opening with said end slotted flaps folding downwardly over said central wall, or (d) combinations thereof, said blank comprising: a central pair of parallel fold lines disposed in a spaced apart relationship to define therebetween a top wall portion for forming said top wall, said top wall portion having at least one opening portion for forming said top wall opening;   a second pair of parallel fold lines spaced outwardly from and parallel to said central pair of parallel fold lines to define therewith a pair of side wall portions for forming said side walls;   a third pair of parallel fold lines spaced outwardly from and parallel to said second pair of parallel fold lines intermediate said outer periphery to define with said second pair of parallel fold lines a pair of bottom wall portions for forming said bottom wall and to define with said outer periphery a pair of central wall portions for forming said central wall, said central wall portions each having a pair of .[.quarter-round.]. cut-outs disposed for mutual registry at the longitudinal ends of said top wall opening and configured to enable the folding of said flaps over said central wall.   
     
     
       2. The paperboard blank of claim 1 which additionally has openings in each of said sidewall portions disposed for registry so that the fork of a forklift can penetrate therethrough. 
     
     
       3. The paperboard blank of claim 1 wherein said flaps are .[.provided with.]. .Iadd.formed from .Iaddend.said runner top wall portion. 
     
     
       4. The paperboard blank of claim 1 wherein said flaps are .[.provided with a rectangular.]. .Iadd.formed from an .Iaddend.insert which has a pair of end slotted flaps which insert fits into said top wall portion opening, said end slotted flaps folding downwardly into said .[.quarter-round.]. cut-outs. 
     
     
       5. A paperboard pallet comprising a top deck and bottom deck having multiple runners interposed therebetween and attached thereto, said runners comprising a sheet of paperboard that has been folded into a rectangular form by (a) one end being folded to form a first bottom wall, a first side wall, a first top wall, and a second side wall; and   (b) the other end being folded in an "S" configuration to form a central vertical wall, a part second top wall which lays against said first top wall, and a part second bottom wall which lays against said first bottom wall;   said top wall having openings, .[.said central vertical wall having quarter-round cutouts located at the longitudinal ends of said top wall openings;.]. said top wall openings receiving flaps which have central slots cut in them, said flaps selected from (a) flaps .[.provided with.]. .Iadd.formed from .Iaddend.said runner top wall, (b) flaps provided with an upper deck attached to said runner, (c) flaps provided with .[.a rectangular.]. .Iadd.an .Iaddend.insert which has a pair of end slotted flaps which insert fits into said top wall opening with said end slotted flaps folding downwardly into said .[.quarter-round cut-outs.]. .Iadd.central wall, .Iaddend.or (d) combinations thereof.   
     
     
       6. The paperboard pallet of claim 5 wherein said flaps are not engaged in said central wall .[.quarter-round cut-outs.]. so that said pallet is in a collapsed state. 
     
     
       7. The paperboard pallet of claim 5 wherein said flaps are engaged in said central wall .[.quarter-round cut-outs.]. so that said pallet is in a rigid formed state for use. 
     
     
       8. The paperboard pallet of claim 5 which additionally has openings in each of said sidewalls disposed in registry so that the fork of a .[.forklike.]. .Iadd.forklift .Iaddend.penetrate therethrough. 
     
     
       9. The paperboard pallet of claim 5 wherein said flaps are .[.provided with.]. .Iadd.formed from .Iaddend.said runner top wall. 
     
     
       10. The paperboard pallet of claim 5 wherein said flaps are .[.provided with a rectangular.]. .Iadd.formed from an .Iaddend.insert which has a pair of end slotted flaps which insert fits into said top wall cut-out with said end slotted flaps folding downwardly into said .[.quarter-round cutouts.]. .Iadd.central wall. .Iaddend. 
     
     
       11. The paperboard pallet of claim 5 wherein said flaps are a combination of (a) and (c). 
     
     
       12. The paperboard pallet of claim 5 wherein .[.U-shaped.]. inserts having a pair of oppositely-disposed, end slotted flaps are inserted into said top wall openings and said slotted flaps engage said central wall .[.quarter-round cut-outs.].. 
     
     
       13. A paperboard pallet comprising an upper deck and a lower deck having a plurality of runners interposed therebetween and affixed to each of said sheets, each of said runners comprising a sheet of paperboard that has been folded into a rectangular form having top and bottom walls, a pair of side walls, and a central vertical wall interposed between said side walls; the top wall having cut-out areas, the central wall having slots located at the longitudinal ends of said top wall cut-out areas; said top wall cut-out areas receiving .[.a U-shaped.]. .Iadd.an .Iaddend.an insert which has a pair of end slotted flaps which insert fits into said top wall cut-out area with said end slotted flaps folding downwardly into said central wall slots. 
     
     
       14. A paperboard runner, suitable for use in forming a paperboard pallet composed of a top and bottom sheet having multiple runners interposed therebetween and attached thereto, which comprises: a sheet of paperboard that has been folded into a rectangular form having top and bottom walls, a pair of side walls, and a central vertical wall .[.provided with.]..Iadd.formed from .Iaddend.ends of said sheet and interposed between said side walls; the top wall having openings, .[.the central wall having quarter-round cut-outs located at the longitudinal ends of said top wall openings;.]. said top wall openings receiving flaps having central slots cut in them, said flaps a combination of (a) flaps .[.provided with.]. .Iadd.formed from .Iaddend.said runner top wall, and (b) flaps provided with .[.a rectangular.]. .Iadd.an .Iaddend.insert which has a pair of end slotted flaps which insert fits into said top wall opening with said end slotted flaps folding downwardly into said .[.quarter-round cut-outs.]. .Iadd.central wall. .Iaddend. 
     
     
       15. A paperboard runner, suitable for use in forming a paperboard pallet composed of a top and bottom sheet having multiple runners interposed therebetween and attached thereto, which comprises: a sheet of paperboard that has been folded into a rectangular form having top and bottom walls, a pair of side walls, and a central vertical wall .[.provided with.]. .Iadd.formed from .Iaddend.ends of said sheet and interposed between said side walls; the top wall having openings, .[.the central wall having quarter-round cut-outs located at the longitudinal ends of said top wall openings;.]. said top wall openings receiving flaps having central slots cut in them, said flaps selected from (a) flaps .[.provided with.]. .Iadd.formed from .Iaddend.said runner top wall, (b) flaps provided with an upper deck attached to said runner, (c) flaps provided with .[.a rectangular.]. .Iadd.an .Iaddend.insert which has a pair of end slotted flaps which insert fits into said top wall opening with said end slotted flaps folding downwardly into said .[.quarter-round cut-outs.]. .Iadd.central wall, .Iaddend.or (d) combinations thereof; and   .[.U-shaped.]. inserts having a pair of oppositely disposed slotted flaps inserted into said top wall openings, said slotted flaps engaging said central wall .[.quarter-round cut-outs.]..   
     
     
       16. A paperboard pallet comprising an upper deck and a lower deck having a plurality of runners interposed therebetween and affixed to each of said decks, each of said runners comprising a sheet of paperboard that has been folded into a rectangular form having top and bottom walls, a pair of side walls, and a central vertical wall interposed between said side walls; the top wall having openings, .[.the central wall having quarter-round cut-outs located at the longitudinal ends of said top wall openings;.]. said top wall openings receiving flaps having central slots cut in them, said flaps a combination of (a) flaps .[.provided with.]. .Iadd.formed from .Iaddend.said runner top wall, and (b) flaps provided with .[.a rectangular.]. .Iadd.an .Iaddend.insert which has a pair of end slotted flaps which insert fits into said top wall opening with said end slotted flaps folding downwardly into said .[.quarter-round cut-outs.]. .Iadd.central wall.Iaddend.. 
     
     
       17. A paperboard pallet comprising: an upper deck;   a lower deck;   a plurality of runners interposed between and affixed to each of said decks, each of said runners comprising a sheet of paperboard that has been folded into a rectangular form having top and bottom walls, a pair of side walls, and a central vertical wall interposed between said side walls; the top wall having openings, .[.the central wall having quarter-round cut-outs located at the longitudinal ends of said top wall openings;.]. said top wall openings receiving flaps having central slots cut in them, said flaps selected from (a) flaps .[.provided with.]. .Iadd.formed from .Iaddend.said runner top wall; (b) flaps provided with an upper deck attached to said runner; (c) flaps provided with .[.a rectangular.]. .Iadd.an .Iaddend.insert which has a pair of end slotted flaps which insert fits into said top wall opening with said end slotted flaps folding downwardly into said .[.quarter-round cut-outs.]. .Iadd.central wall, .Iaddend.or (d) combinations thereof; and   .[.U-shaped.]. inserts having a pair of oppositely-disposed, end slotted flaps inserted into said top wall openings, said slotted flaps engaging said central wall .[.quarter-round cut-outs.]..