Paper-Based Pallet

Abstract

A paper-based pallet includes paper-based material top and bottom decks spaced apart by wound paperboard tubes. The decks are formed either by a single piece of paper-based material folded in C-shaped fashion or by two separate pieces of paper-based material. At least at one side of the pallet, flaps extend from the top deck and corresponding flaps extend from the bottom deck. The flaps are arranged in pairs each having a flap from the top deck overlapping a flap from the bottom deck, the overlapping flaps being secured together. Tine-receiving openings can be defined between adjacent pairs of flaps. The top deck can be reinforced at each opening by a flap hinged to the top deck and folded 180 degrees into contact with the top deck and secured thereto, thus forming a double-layer edge portion of the top deck.

What is claimed is: 
     
         1 . A paper-based pallet, comprising:
 a top deck comprising a first sheet of paper-based material;   a bottom deck comprising a second sheet of paper-based material; and   a plurality of spacers formed as separate parts from the first and second sheets and disposed between and affixed to the first and second sheets such that a vertical space is defined between the top and bottom decks;   wherein at one side of the pallet the first sheet defines a first flap comprising an integral portion of the first sheet extending from an edge of the top deck and the second sheet defines a second flap comprising an integral portion of the second sheet extending from an edge of the bottom deck, the first and second flaps being folded down and up, respectively, to extend vertically, and the first and second flaps overlapping and being secured to each other.   
     
     
         2 . The pallet of  claim 1 , wherein there are a plurality of first flaps from the first sheet spaced apart along said one side of the pallet and a plurality of second flaps from the second sheet spaced apart along said one side, the flaps forming pairs each comprising a first flap overlapped with a second flap and secured to each other. 
     
     
         3 . The pallet of  claim 2 , wherein there are three said pairs of first and second flaps at said one side of the pallet. 
     
     
         4 . The pallet of  claim 3 , wherein the pairs are spaced apart so as to define two spaced tine-receiving openings at said one side for receiving tines of a forklift. 
     
     
         5 . The pallet of  claim 4 , wherein the first sheet defines reinforcing flaps at the locations of the two openings at said one side of the pallet, said reinforcing flaps being folded 180 degrees relative to the top deck so as to contact the top deck and being secured to the top deck to form a double-layer edge portion adjacent each of the openings at said one side of the pallet. 
     
     
         6 . The pallet of  claim 5 , wherein the first and second sheets are two separate pieces, and wherein at another side of the pallet opposite from said one side the first sheet defines a plurality of first flaps spaced apart along said other side of the pallet and a plurality of second flaps from the second sheet spaced apart along said other side, the flaps forming pairs each comprising a first flap overlapped with a second flap and secured to each other. 
     
     
         7 . The pallet of  claim 6 , wherein there are three said pairs of first and second flaps at said other side of the pallet. 
     
     
         8 . The pallet of  claim 7 , wherein the pairs are spaced apart so as to define two spaced tine-receiving openings at said other side for receiving tines of a forklift. 
     
     
         9 . The pallet of  claim 8 , wherein the first sheet defines reinforcing flaps at the locations of the two openings at said other side of the pallet, said reinforcing flaps being folded 180 degrees relative to the top deck so as to contact the top deck and being secured to the top deck to form a double-layer edge portion adjacent each of the openings at said other side of the pallet. 
     
     
         10 . The pallet of  claim 1 , wherein the first and second sheets are portions of a single continuous piece of paper-based material, said piece of paper-based material being folded at another side of the pallet opposite from said one side so as to form a side wall at said other side, the side wall extending between and connecting the top deck to the bottom deck at said other side. 
     
     
         11 . The pallet of  claim 10 , wherein there are a plurality of first flaps from the first sheet spaced apart along said one side of the pallet and a plurality of second flaps from the second sheet spaced apart along said one side, the flaps forming pairs each comprising a first flap overlapped with a second flap and secured to each other. 
     
     
         12 . The pallet of  claim 11 , wherein there are three said pairs of first and second flaps at said one side of the pallet. 
     
     
         13 . The pallet of  claim 12 , wherein the pairs are spaced apart so as to define two spaced tine-receiving openings at said one side for receiving tines of a forklift. 
     
     
         14 . The pallet of  claim 13 , wherein the first sheet defines reinforcing flaps at the locations of the two openings at said one side of the pallet, said reinforcing flaps being folded 180 degrees relative to the top deck so as to contact the top deck and being secured to the top deck to form a double-layer edge portion adjacent each of the openings at said one side of the pallet. 
     
     
         15 . The pallet of  claim 14 , wherein the side wall at said other side of the pallet defines two spaced tine-receiving openings. 
     
     
         16 . The pallet of  claim 15 , wherein the openings at said other side are created by two spaced reinforcing flaps cut out from the side wall and hingedly connected to the top deck, said reinforcing flaps being folded 180 degrees relative to the top deck so as to contact the top deck and being secured to the top deck to form a double-layer edge portion adjacent each of the openings at said other side of the pallet. 
     
     
         17 . The pallet of  claim 1 , wherein the spacers comprise wound paperboard tubes each oriented with an axis of the tube extending vertically.