Pallet formed from molded fibrous panel material

Abstract

A pallet is constructed of a molded fibrous panel material comprising a sheet portion defining opposite planar surfaces, and a grid of intersecting ribs projecting from one of the planar surfaces of the sheet portion, the sheet portion and ribs being integrally molded from fibrous material. The pallet comprises a horizontal portion of the molded fibrous panel material forming an upper support surface of the pallet, and at least two spaced runners joined to the horizontal portion for engaging the ground to space the horizontal portion above the ground. Each runner comprises at least two vertical portions of the molded fibrous panel material arranged in parallel relation and bonded to one another. In one embodiment, a single panel member is folded along a series of parallel fold lines extending across a width of the member, so as to form the runners and the horizontal portion from the single member.

1 . A pallet formed predominately of molded fibrous material, comprising: 
 a molded fibrous panel material comprising a sheet portion defining opposite planar surfaces, and a grid of intersecting ribs projecting from one of the planar surfaces of the sheet portion, the sheet portion and ribs being integrally molded in one piece from fibrous material;    a horizontal portion of said molded fibrous panel material forming an upper support surface of the pallet;    the pallet further comprising at least two spaced runners joined to and extending downward from the horizontal portion for engaging the ground to space the horizontal portion above the ground, each runner comprising at least two vertical portions of the molded fibrous panel material arranged in parallel relation and bonded to one another.    
   
   
       2 . The pallet of  claim 1 , wherein each runner includes a separate stiffening member disposed between and bonded to two of the vertical portions.  
   
   
       3 . The pallet of  claim 1 , wherein the horizontal portion and the vertical portions are all integrally and serially joined together along a series of spaced parallel fold lines in the molded fibrous panel material.  
   
   
       4 . The pallet of  claim 3 , wherein each fold line comprises a groove in the molded fibrous panel material.  
   
   
       5 . The pallet of  claim 4 , wherein the grooves are molded into the molded fibrous panel material.  
   
   
       6 . The pallet of  claim 4 , wherein the grooves are formed by mechanically removing fibrous material from the molded fibrous panel material.  
   
   
       7 . The pallet of  claim 4 , wherein at least some of the grooves are generally V-shaped with an included angle of about 90 degrees between opposite side walls of the groove.  
   
   
       8 . The pallet of  claim 1 , further comprising a top panel affixed atop the horizontal portion.  
   
   
       9 . The pallet of  claim 8 , wherein the top panel comprises a multi-ply laminated material.  
   
   
       10 . The pallet of  claim 9 , wherein the laminated material comprises paperboard.  
   
   
       11 . The pallet of  claim 8 , wherein the top panel comprises another piece of the molded fibrous panel material.  
   
   
       12 . The pallet of  claim 11 , wherein the ribs of the top panel face downward and the ribs of the horizontal portion face upward to oppose the ribs of the top panel.  
   
   
       13 . The pallet of  claim 12 , wherein the ribs of the top panel are bonded directly to the ribs of the horizontal portion.  
   
   
       14 . The pallet of  claim 12 , wherein the ribs of the top panel are joined to the ribs of the horizontal portion via an intervening piece of sheet material disposed therebetween, said sheet material being bonded to the ribs of the top panel and horizontal portion.  
   
   
       15 . The pallet of  claim 3 , wherein the molded fibrous panel material forming the horizontal and vertical portions comprises a single layer of the molded fibrous panel material.  
   
   
       16 . The pallet of  claim 3 , molded fibrous panel material forming the horizontal and vertical portions comprises two layers of the molded fibrous panel material joined rib-to-rib.  
   
   
       17 . The pallet of  claim 3 , further comprising a reinforcing web bonded to one side of the molded fibrous panel material along at least one of the fold lines.  
   
   
       18 . The pallet of  claim 17 , wherein the reinforcing web comprises a pressure-sensitive adhesive tape.  
   
   
       19 . The pallet of  claim 3 , wherein the molded fibrous panel material has, in order, from one end to an opposite end of the molded fibrous panel material: 
 first, second, and third fold lines for forming a first runner;    fourth, fifth, sixth, and seventh fold lines for forming a second runner; and    eighth, ninth, and tenth fold lines for forming a third runner.    
   
   
       20 . The pallet of  claim 1 , wherein the molded fibrous panel material is formed from recycled paper fibers.  
   
   
       21 . The pallet of  claim 20 , wherein the molded fibrous panel material is impregnated with a resin for rendering the molded fibrous panel material substantially water-resistant.  
   
   
       22 . The pallet of  claim 1 , wherein each runner comprises a first pair of layers of the molded fibrous panel material joined rib-to-rib.  
   
   
       23 . The pallet of  claim 22 , wherein each runner comprises a second pair of layers of the molded fibrous panel material joined rib-to-rib and joined to the first pair such that the runner comprises four layers.  
   
   
       24 . The pallet of  claim 22 , wherein the horizontal portion comprises a separate piece of the molded fibrous panel material joined to the runners.