Configurable Pallet

This application is a Continuation patent application and claims the benefit of and priority to U.S. non-Provisional patent application Ser. No. 18/505,872, filed Nov. 9, 2023, which claims the benefit of and priority to U.S. non-Provisional patent application Ser. No. 17/599,483, filed Sep. 28, 2021, which issued as U.S. Pat. No. 11,840,371, incorporated herein by reference in its entirety, which is a National Phase Application of International Patent Application No. PCT/US2020/025552, filed Mar. 27, 2020, incorporated herein by reference in its entirety, which claims the benefit of and priority to U.S. Provisional Patent Application No. 62/826,867, filed Mar. 29, 2019, incorporated herein by reference in its entirety.

This disclosure generally relates to a configurable pallet to support items, goods, and the like, and to provide a holding platform for the transportation of goods.

Conventional pallets are heavy, flat transport structures for supporting goods in a secure manner when the structures are lifted by a vehicle, such as a forklift. Other lifting equipment may be used, including a pallet jack, a front loader, a jacking device, or a crane. Goods placed on a pallet may be secured with strapping, stretch wrap, or shrink wrap. Such pallets may be made, generally, of wood or plastic, are expensive to purchase, and often are not durable, resulting in high costs for repair or replacement.

Very often, pallets are made according to a standard size, depending on a particular industry. Such standardized sizes require a particular shipping configuration to fully load a pallet or the transportation of the shipment may not be efficient. Standardized sizes may not be readily available or may not be available for undersized or oversized goods, or custom orders. Further, the storage of empty pallets is cumbersome and costly. Often, empty pallets have to be stored or shipped back to other locations for future storage and use, all of which is expensive and undesirable. Pallets may not be recyclable at all or may not be readily recyclable.

This summary is provided to introduce various implementations that are further described below in the detailed description. This summary is neither intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter. At a high level, this disclosure presents one implementation of a configurable pallet system that enables efficient production of pallets on demand according to specified dimensions regardless of any pallet standards. The disclosed configurable pallet, its system, and the methods of manufacturing thereof allow a user to configure a load-bearing platform to carry virtually any specific ordered packaging dimensions of goods. Before assembly, the components of the configurable pallet can be stored in a compact, efficient manner, saving, in certain implementations and situations, thirty times or more the space required to store traditional pallets. Such space saving capabilities enable efficient storage and transportation. Further, the weight of the configurable pallet is substantially less than traditional pallets, saving energy and costs during transportation, whether by air or ground transportation. Various other advantages may be provided in certain implementations of the configurable pallet, system, and methods.

In a first general aspect or possible implementation, a configurable pallet, which may be referred to as a load-bearing platform, for supporting goods may include a plastic base having two or more protrusions connected by one or more bridge pieces and a cardboard base having openings spaced apart a distance. The two or more protrusions are spaced apart the distance, or some distance such that the protrusions may be placed in or through the openings. The openings are configured to receive the two or more protrusions of the plastic base. The load-bearing platform may further include a load distribution member configured to contact at least a portion of the plastic base. The load distribution member supports at least a portion of the goods and distributes at least a portion of the weight of the goods to at least a portion of the plastic base.

It should be noted that the term “cardboard” as used herein may refer to any material that may be provided as a sheet or roll and have certain mechanical properties as those of a wood fiber or paper-based materials or sheets. In certain embodiments or implementations, the cardboard may be a poster board, a paperboard, a corrugated fiberboard, a non-woven sheet or material, and the like. The cardboard may be recyclable. In some embodiments, the cardboard may be a heavy-duty paper-based board made of recyclable materials or biomass materials that can be cut by a knife, laser, and/or jet, and may also include other paper forming methods, such as stamping, rolling, among others. In other embodiments, the cardboard may be plastic, polymer fiber, cellulose, and/or cellulose fiber based, such as a sheet of plastic, epoxy, glass fiber, composite fiber, cellulose fiber, nonwoven fiber, or a mixture thereof, which may also be cut and formed using methods similar to or equivalent to paper-based cardboards. Computer numerical controlled machines may be used to cut the cardboard, regardless of specific material composition, into desired shapes for folding and/or bending into the configurable pallets disclosed herein.

In a specific aspect, the load-bearing platform may further include a cardboard top, piece, or sheet that serves as at least a portion of the load distribution member and connects or contacts at least a portion of the bridge piece, and, in certain implementations, also the cardboard base. The cardboard top supports at least a portion of the goods placed thereon.

In another specific aspect, the cardboard base may further include at least one or more peripheral walls in a vertical position or upward angled position. In some embodiments, the cardboard base includes four peripheral walls. The peripheral walls prevent relative side movements between the loaded goods and the load-bearing platform.

In yet another specific embodiment, the cardboard base may be positioned in a flat horizontal position during production, storage, and transportation. The at least one peripheral wall is folded from the flat horizontal position to the vertical position. In some embodiments, the at least one folded peripheral wall abuts against or may be adjacent to the plastic base when the plastic base is fully inserted into the cardboard base.

In another example implementation, the plastic base may include a side wall extending substantially orthogonally (or some other angle) upward from a side edge of the bridge piece. The side wall of the base may be enclosed into or adjacent the at least one folded peripheral wall of the cardboard base in one embodiment, and not enclosed in another.

In another specific aspect, the bridge piece is affixed onto the cardboard base using an adhesive, or some mechanical coupling or binding.

In yet another specific aspect, the plastic base is shaped such that the protrusions of the plastic base can stack within another identical or similar plastic base.

In a specific aspect, the plastic base includes three protrusions and two bridge pieces. In some embodiments, the load-bearing platform further includes two additional plastic bases. The three plastic bases may include three protrusions so as to provide nine protrusions in total. The cardboard base may include at least nine openings configured to receive the nine protrusions. Of course, any desired number of protrusions may be provided in a plastic base and corresponding openings in the cardboard base, such as 2×2, 3×3, 4×4, 5×5, 2×3, 2×4, etc., or any desired or needed number of protrusions. These arrangements may be symmetrical or asymmetrical, as desired. Different types or configurations of plastic bases may be used in a configurable pallet or load-bearing platform as provided and taught herein.

In another example aspect, the load-bearing platform further includes a number of plastic bases with two or more protrusions. The protrusions are legs for providing a space between the cardboard base and a ground surface. The space may allow a tool or member, such as a forklift to insert a fork underneath the cardboard base. In some example embodiments, the protrusions may include a textured surface in contact with the ground surface. The textured surface may either increase friction with the ground surface by increasing contact pressures or decrease friction with the ground surface, which may allow a loaded configurable pallet to be more easily maneuvered on a surface, such as by sliding on the bottom textured surface of the protrusions of the plastic base or bases.

In yet another specific aspect, the plastic bases may be stacked and stored together by inserting the protrusions of one of the plastic bases into the open or hollowed back sides of the corresponding protrusions of another of the plastic bases. In certain implementations, this may be similar to stacking drinking cups within one another, and may provide convenient and efficient storage.

In one specific aspect, the cardboard base includes a first set of cut lines or folds for removing pieces to create the openings, and a second set of cut lines or folding lines for folding up the at least one peripheral wall.

In yet another aspect, the disclosure presents a method for making a configurable pallet for supporting goods. The method includes providing or producing a plastic base with a first dimension distance between at least two protrusions. The plastic base has two or more protrusions spaced apart by the first dimension and connected by a bridge piece. A cardboard base is provided or produced with multiple openings therein. The openings correspond to the two or more protrusions of the plastic base spaced to receive the protrusions of the plastic base, such as, in one implementation, spaced apart by the first dimension. The two or more protrusions of the plastic base may be inserted into the openings of the cardboard base to form the configurable pallet.

The method may further include producing a cardboard top sized to cover all or a portion of the cardboard base and at least a portion of the bridge piece to support at least a portion of the goods. This may be referred to as a load distribution member. Just as with the cardboard base, the load distribution member may be made of cellulose or plastic.

In another specific aspect, the method may further include applying adhesives between a bottom surface of the bridge piece of the plastic base and the cardboard base. In other implementations, a coupling, such as a mechanical coupling or a friction fit may be provided between the bridge piece of the plastic base and the cardboard base.

In yet another aspect, producing a plastic base may include producing a plurality of plastic bases. In some embodiments, producing a cardboard base includes producing a plurality of openings corresponding to the two or more protrusions of the plurality of produced plastic bases and wherein inserting the two or more protrusions of the plastic base includes the two or more protrusions of the plurality of plastic tops into the plurality of openings of the cardboard.

In one implementation, producing the cardboard base further includes stamping, laser cutting, or machining the cardboard base to make the plurality of openings. In some embodiments, producing the cardboard base further includes receiving a length dimension and a width dimension defining a surface area of the cardboard base or area to be covered with goods.

In another specific aspect, producing the cardboard base further includes producing a side tab foldable into a peripheral wall abutting against the plastic base when the protrusions of the plastic base are fully inserted into the cardboard base. In some embodiments, producing the plastic base with the first dimension further includes producing a side wall extending substantially orthogonally upward or at some other desired angle from a side edge of the bridge piece. The side wall of the plastic waste may extend continuously or contain gaps or openings, and may be enclosed into the folded peripheral wall of the cardboard base or may be left uncovered.

In another aspect, a configurable pallet may include a cardboard base having an array of openings and two or more plastic bases. The array of openings may include an opening spacing dimension and a coverage area, both specified by a user. Two or more of the plastic bases having two or more protrusions connected by a bridge piece and spaced apart at some position by the opening spacing dimension. The two or more protrusions may be inserted into the array of openings in the cardboard (and may allow the plastic bases to be stackable within one another in certain implementations). The configurable pallet further includes a cardboard member or load distribution member positioned at least partially over one or more bridge pieces of the two or more plastic bases and a part of the cardboard base, the cardboard top at least partially supporting goods placed thereon.

In a specific aspect, the configurable pallet may further include a sleeve configured to be supported by the plastic bases and the cardboard base, and to surround the goods or items placed on the configurable pallet.

In another specific aspect, the configurable pallet may further include a cardboard lid configured to fit over a top opening in the sleeve. For example, the cardboard lid may be a folded piece having similar side walls as the cardboard base, except that the cardboard lid does not include openings for receiving plastic bases.

In yet another specific aspect, the sleeve may be provided as two pieces of angled cardboard or other desired material. For example, each of the two angled cardboard pieces may be configured as an “L” shaped insert covering two sides of the loaded goods, so as to completely surround all four sides of the loaded goods or cargo. This allows one person to easily remove the sleeve without the need for a ladder or other tools. This may be especially convenient in a retail display environment where one worker at a retail store may simply remove the two pieces of angled cardboard to display merchandise for sale.

In another aspect, a method for making a configurable pallet includes receiving a plastic base having two or more protrusions; the two or more protrusions spaced apart by a first dimension and connected by a bridge piece. A second dimension may be received defining a distance between two pieces of the plastic base. A cardboard base is produced with multiple openings using the first dimension and the second dimension. Each of the multiple openings fitting one of the two or more protrusions. The two or more protrusions of two or more pieces of the plastic base are inserted into the multiple openings to form the configurable pallet.

Like elements are indicated with like reference numerals.

Embodiments disclosed herein present a configurable pallet, which may also be referred to as a load-bearing platform, that can be customized to desired specified sizes. The configurable pallet may include three components to be made according to specific dimensions. As a result, the configurable pallet may be ordered to fit virtually any amount and any size products for transportation, including various shipping arrangements of such products or goods. This may decrease or remove a need to store large quantities of standardized pallets that may not provide a platform size to fit a specific shipment. Two or more configurable pallets of a customized size may be stacked together. Unlike conventional pallets, which are heavy and usually provide a flat surface for receiving generic goods, the configurable pallets are light weight, normally recyclable, may contain stackable components, and may include peripheral side walls for receiving specifically packaged goods to avoid relative side movements. Other benefits may be appreciated in view of the following detailed description.

In the following detailed description and the attached drawings and appendices, numerous specific details are set forth to provide a thorough understanding of the present disclosure. However, those skilled in the art will appreciate that the present disclosure may be practiced, in some instances, without such specific features or details. In other instances, well-known elements have been illustrated in schematic or block diagram form in order not to obscure the present disclosure in unnecessary detail. Additionally, for the most part, specific details, and the like, have been omitted inasmuch as such details are not considered necessary to obtain a complete understanding of the present disclosure, and are considered to be within the understanding of persons of ordinary skill in the relevant art.

Turning generally to,illustrates an exploded perspective view of an example configurable palletillustrating, among other items, an arrangement of openingsof a cardboard base.illustrates a flattened or top view of the bottom piece of the example configurable palletshown in.respectively illustrate a front view, a side view, and a top view of an example plastic base that may be used in the example configurable palletshown in.

The configurable palletmay be a customizeable load-bearing platform for supporting goods or objects arranged in various configurations as desired. The configurable palletmay include a cardboard base, one or more plastic bases(which may be implemented or shaped as plastic basesof), and a load distribution memberthat may be implemented as a cardboard top or sheet. The plastic basehas two or more protrusionsconnected by one or more bridge pieces(see). The two or more protrusionsspaced apart a distance. In some embodiments, the distanceis a standard value. In other embodiments, the distancemay be customized or vary within one plastic base with multiple protrusions.

The cardboard basehas openingsspaced apart the distancein one direction and, in other embodiments, may be spaced a different distance in an orthogonal direction between the openings, such as distance. The openingsare configured to receive the two or more protrusionsof the plastic base. The load distribution memberis configured to contact at least a portion of the plastic basefor distributing the loads from the load distribution memberto the plastic bases. The load distribution membermay support at least a portion of the goods placed thereon and distributes at least a portion of the weight of the goods to one or more of the plastic base. In an embodiment, the cardboard basehas nine openings in an array of three by three. This allows for inserting three plastic basesthere through. Each of the three plastic basesincludes three protrusions in this example. The protrusions may have a clearance heightsufficient to allow equipment, such as a forklift, to handle, lift, or move a loaded load-bearing platform.

In some embodiments, the configurable pallet(which also may be referred to as the load-bearing platform) uses a cardboard topas the load distribution member. For example, the cardboard topmay be made of a same or similar dimension as the cardboard base, or may be provided as strips or pieces covering only a portion of the bridge pieceof the plastic baseand/or the cardboard base. The cardboard topmay sandwich the bridge piecewith the cardboard base. The cardboard topis used to support at least a portion of the goods placed thereon and distribute the weight of the goods to one or more of the plastic basesand onto the cardboard base.

In, the cardboard baseincludes a bottom configurable lengthand a bottom configurable width. These two dimensions may be customized based on specific packaging sizes on demand or as desired. Similarly, the number and locations of openingsmay also be configured, such as to allow a forklift to handle the loaded platform at a corresponding center of gravity toward a particular location, if not at the center. The load distribution membermay have a top configurable lengthand a top configurable widthbeing the same as or different from the respective bottom configurable lengthand the bottom configurable width.

As shown in, the cardboard basemay further include at least one peripheral wallfolded in a vertical position to prevent or minimize relative lateral movements between the configurable palletand the goods placed thereon. Turning now to, the cardboard basefurther includes, in this implementation, four peripheral wallsfoldable from pre-cut geometries. For example, at least one peripheral wallmay be folded from a flat horizontal position to the vertical position, such that the cardboard basemay be cut and creased using a numerically controlled machine. When folded, the at least one folded peripheral wallmay abut against or be positioned adjacent the plastic basewhen the plastic baseis fully inserted into the cardboard base, as shown in.

Turning now to, an example pre-cut pattern for the cardboard baseis shown. In the illustrated example, a rectangular profile is used. However, the configurable palletmay be cut into different shapes under the same working principle that may or may not be square or symmetrical. In, each side of the rectangle may include a peripheral wall outer side(and) and a peripheral wall inner side(and) when folded, divided by a dashed (or serrated) cutline or crease(and) facilitating folding. Tabsmay be pre-cut to reinforce the connection between the folded walls. The configurable palletmay allow user specific marginsandto be provided in order to have goods fit tightly or as desired into the folded peripheral walls(). In some embodiments, the cardboard baseincludes a first set of cut lines (e.g., defining the openings) for removing pieces to create the openingsand a second set of cut lines (e.g., the creasesand) for folding up the peripheral walls.

Depending on the required load distribution, a spacing distanceandmay also be defined to include additional plastic bases. For example, although three plastic bases(each with three protrusions) correspond to the nine openings for the example shown in, the distanceand/ormay be reduced (or adjusted as desired) to allow for four plastic basesfor providing a more even loads distribution if the loaded goods have a greater weight. Although the distanceand the distanceare shown as generally the same, in other embodiments, these spacing distances between openingsmay be different as desired.

In some embodiments, as shown in, the inner sidesandof the peripheral wallsmay include or serve as an extended portionto partially overlap with the plastic basein the place of (or in addition to) the cardboard top. That is, the extended portionmay serve as a load distribution member, such as the load distribution member or the cardboard top, and thus a full coverage cardboard top piece may be eliminated or reduced, if desired.

Turning now to, details of the plastic baseare illustrated. The plastic base, as shown, may include two or more protrusionsand a continuous or discrete (or spaced) side wall. In other embodiments, the side wallis not provided. One or more of the protrusionsmay include a textured bottom surface. The plastic basemay be shaped such that the plastic basecan overlap and stack upon another plastic base, for example, when the protrusionsare hollow and can be stacked like foam or plastic cups. That is, the plastic baseand additional plastic basescan be stacked together by inserting the protrusionsof one of the plastic basesinto the hollow openingsof the protrusionsof another. This provides for efficient storage of such components.

The plastic baseincludes a separated (illustrated) or continuous side wallextending substantially orthogonally upward from a side edge of the bridge piece. In other embodiments, the side wallmay extend upwardly at any desired angle. The side wallmay be enclosed into the folded peripheral wallsof the cardboard baseto provide increased bending stiffness and material reinforcement. For example, the plastic basemay be immune to water or moisture damage and thus more reliable than the folded side wallsof the cardboard base.

In some embodiments, the bridge piecemay be affixed onto the cardboard baseusing an adhesive (not shown). The adhesive may be a resin, a thermoplastic, or the like or other desired adhesive. The adhesive may further prevent local delamination, in addition to the folded peripheral wallskeeping the cardboard basemounted with one or more of the plastic bases. In other embodiments the bridge piecemay be affixed to the cardboard baseusing any available or desired mechanical coupling or linkage, including, for example, friction fit or threaded couplings.

In the illustrated embodiment, the plastic baseincludes three protrusionsand two bridge pieces. However, in other embodiments, a different number of protrusions may be used or configured. The bridge piecesare shown to be of the same length, however, in different configurations, they may be configured as different lengths.

Turning now to, the configurable palletare shown to include three plastic bases. Each of the three plastic basesincludes three protrusionsthat extend below (not shown) the cardboard baseso as to provide nine protrusionsin total. The cardboard basehas nine openingsfor receiving the nine protrusions. The nine protrusionsserve as legs (not shown) for providing a space between the cardboard baseand a ground surface. The space allows a member or tool, such as a forklift to insert a fork underneath the cardboard base. Each of the nine protrusionsmay include a textured bottom surfacethat will be in contact with the ground surface when in use.

In some embodiments, the configurable palletincludes a cardboard basehaving an array of openings. The array may include an opening spacing dimension,, or as desired by a user, and a coverage area specified by a user. The configurable palletmay further include two or more plastic bases, which are normally separate but could include some linkages, such as plastic linkages if formed from the same mold. Each of the two or more plastic basesmay have two or more protrusionsconnected by a bridge pieceand spaced apart by a user-defined opening spacing dimension,, or as desired or as needed. The two or more protrusionsmay be sized similarly or differently, and are to be inserted into the array of openings. A cardboard top, or extended portion, may sandwich the bridge piecewith the cardboard baseand support goods placed thereon.

Turning now to, these figures illustrate perspective views of variations of an embodiment of an assembled configurable palletwith protective side sleeve(s)(andin other embodiments) and a lid. In one embodiment, the side sleeveis one piece that surrounds the cargo or goods stored on the configurable pallet. In, the sleeveis configured to be supported at least partially, in one implementation, by the plastic basesand the cardboard base, and to surround the goods placed on the configurable pallet. In some embodiments, the cardboard lidis included and configured to fit over a top opening in the sleevesand.

In, the sleevesandmay be provided as an upper portion sleeveand a lower portion sleevefor reducing the storage size, and for ease of installation or positioning of the sleeves. Although the upper portion sleeveand the lower portion sleeveare illustrated, three or more of the sleeve portions may be provided to cover the sides of the loaded cargo. This may reduce the storage size for each sleeve portion and increase the versatility when multiple sleeves are stacked together to cover a desired height. For example, if each sleeve covers a height of one foot, it would be convenient to stack five sleeves to cover five feet. Further, it is much easier for one person to remove smaller sleeves than one large sleeve, when unpacking the configurable pallet with goods stored thereon.

In, the sleevesandmay be provided as two pieces of angled cardboard, for example, having an “L” shaped cross-section and separated at the edge. The junction between sleeveand sleeveat edgeis not shown in detail in. In some embodiments, this junction may include an inner lip, ledge, fold, overlap, or attachment portion for preventing contaminants from entering through the gap at the junction at the edge. The “L” shaped configuration enables each piece of the sleevesandto be stored flat for saving space, and to be easily and readily placed in position by one person and easily removed without the need for a ladder if the sleeve were one piece. In one implementation, the goods or cargo stored on the configurable palletmay include a point of sale or display such that a worker at a retailer may simply receive the item as shown inat the retail store, place the item at the desired sales location in the retail store, remove the lid, and conveniently remove the sleevesandso that consumers may view and purchase the goods already positioned on the point of sale display. This may provide significant savings and convenience to retailers, while allowing the light-weight, configurable pallet to be easily moved and positioned as desired in a retail store. In certain embodiments, the bottom surfaceof the protrusions(see) may include a texture that serves as “sliders” to reduce sliding friction to allow one or a few personnel to push the configurable pallet across a suitable floor to a desired location while still loaded with goods or products.

is a flow chartillustrating a method for making the example configurable pallet described herein. At, a user may define or receive a dimension defining a distance between two pieces of the plastic baseand/or a dimension between protrusions of a plastic base. The dimension(s) may be as desired, or may be client or goods specific.