US20070266909A1

US20070266909A1 - Nestable Pallet

Info

Publication number: US20070266909A1
Application number: US11/625,557
Authority: US
Inventors: David Wesley Monteith; Jean Francois Ruffet
Original assignee: Conitex Sonoco LLC
Current assignee: Conitex Sonoco LLC
Priority date: 2006-05-18
Filing date: 2007-01-22
Publication date: 2007-11-22

Abstract

A pallet includes a platform having a plurality of openings for carrying an object thereon, and a plurality of legs attached to the platform for supporting the platform above a surface. Each of the legs is positioned in a respective one of each of the platform openings and includes a cone having an upper end proximate the platform and a lower end for resting on the surface. The upper end has a diameter greater than a diameter of the lower end so that a second like pallet can be nested within the first pallet. Each leg can include a bull nose positioned proximate the lower end for providing a stop for the second like pallet nested within the first pallet in order to facilitate separation of the second pallet from the first pallet.

Description

This application claims priority to U.S. Provisional Application No. 60/747,626, filed May 18, 2006.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

The invention relates to pallets for supporting objects and methods for making same. One pallet according to a preferred embodiment of the invention has conical legs that allow for one pallet to be stacked on and nested within another pallet. The legs are made of paper and include a feature that facilitates the separation of nested pallets. Another preferred embodiment of the invention includes a pallet that can be made from a single piece of corrugated paper.
There exists a wide variety of portable pallets for transporting and storing packages and materials, such as in factories, warehouses and vehicles. Nestable pallets are particularly useful in that they allow multiple pallets to be stacked on and nested within each other when they are not carrying any materials. This facilitates movement of the empty pallets and minimizes the space they occupy during transport and storage.
A number of nestable pallets are known. For example, U.S. Pat. No. 5,730,067 to Kohlhaas discloses a nestable pallet comprising an apertured single deck with a number of leg members configured as hollow truncated cones. The deck can be constructed of heavy paper board, corrugated cardboard, wood or plywood, and the legs are made of steel sheet metal or hard plastic. The legs are open at the top, and closed off at the bottom by a generally flat bottom section.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a pallet that can be made of paper, and is capable of carrying substantial loads.
It is another object of the present invention to provide a nestable pallet with legs that can be made of paper that are open at both ends.
It is yet another object of the present invention to provide a pallet that can be nested with another pallet and easily separated from the other pallet.
It is yet another object of the present invention to provide a pallet that can be made of a single sheet of material, such as corrugated paper.
These and other objects of the present invention are achieved in the preferred embodiments of the invention described below. One of the preferred embodiments of the invention includes a pallet having a platform with a plurality of openings for carrying an object thereon, and a plurality of legs attached to the platform for supporting the platform above a surface. Each of the legs is positioned in a respective one of each of the platform openings and includes a cone having an upper end proximate the platform and a lower end for resting on the surface. The upper end having a diameter greater than a diameter of the lower end such that a second like pallet can be nested within the first pallet, and the leg includes a bull nose positioned proximate the lower end for providing a stop for the second like pallet nested within the first pallet to facilitate separation of the second pallet from the first pallet.
According to another preferred embodiment of the invention, the platform includes a plurality of foldable sections positioned proximate the platform openings for providing a surface area contacting the legs, in which the legs are attached to the platform by an adhesive contacting the legs and the surface area of the foldable sections.
According to yet another preferred embodiment, a pallet includes a platform having an upper surface, a lower surface, and a plurality of openings therethrough, and a plurality of legs attached to the platform for supporting the platform above a surface, in which each of the plurality of legs is positioned in a respective one of the platform openings. Each leg includes an outer cone having an upper end proximate the platform and a lower end for positioning on the surface. The upper end defines a diameter greater than a diameter defined by the lower end, and an inner cone is positioned within the outer cone and has an upper end proximate the platform and a lower end opposite the upper end. The upper end defines a diameter greater than a diameter defined by the lower end.
According to another preferred embodiment of the invention, each of the plurality of legs includes a first flared section proximate the upper end of the inner cone and attached to the upper surface of the platform, and a second flared section proximate the upper end of the outer cone and attached to the lower surface of the platform. An area of the platform that defines each of the plurality of openings is sandwiched between the first flared section and the second flared section of each of the legs.
According to another preferred embodiment of the invention, the lower end of the outer cone of each of the legs includes a bull nose defining an area that receives the lower section of the inner cone.
According to another preferred embodiment of the invention, the pallet is made of paper.
According to another preferred embodiment of the invention, the inner cone is sloped at an angle less than the outer cone.
According to another preferred embodiment of the invention, the inner cone is sloped at an angle of about eight degrees, and the outer cone is sloped at an angle of about ten degrees.
According to another preferred embodiment of the invention, the lower end of the outer cone of each of the legs includes a bull nose defining an area that receives the lower end of the inner cone.
According to another preferred embodiment of the invention, an outer surface of the inner cone is attached to an inner surface of the outer cone by an adhesive.

BRIEF DESCRIPTION OF THE DRAWINGS

Some of the objects of the invention have been set forth above. Other objects and advantages of the invention will appear as the invention proceeds when taken in conjunction with the following drawings, in which;

FIG. 1 is a perspective view of a pallet according to a preferred embodiment of the invention;

FIG. 2 is another perspective view of the pallet of FIG. 1;

FIG. 3 is yet another perspective view of the pallet of FIG. 1;

FIG. 4 is yet another perspective view of the pallet of FIG. 1;

FIG. 5 is partial perspective view of the pallet of FIG. 1;

FIG. 6 is a partial cross sectional view of the pallet of FIG. 1;

FIG. 7 is a partial perspective view of the pallet of FIG. 1;

FIG. 8 is another partial perspective view of the pallet of FIG. 1;

FIG. 9 is yet another partial perspective view of the pallet of FIG. 1;

FIG. 10 is a partial cross sectional view of the pallet of FIG. 1;

FIG. 11 is a partial cross sectional view of a pallet according to another preferred embodiment of the invention;

FIG. 11A is a partial cross sectional view of the pallet of FIG. 11, shown in use with a second similar pallet;

FIG. 12 is another partial cross sectional view of the pallet of FIG. 11;

FIG. 13 is a perspective view of a pallet according to another preferred embodiment of the invention;

FIG. 14 is another perspective view of the pallet of FIG. 13;

FIG. 15 is a partial cross sectional view of the pallet of FIG. 14, taken along lines 15-15;

FIG. 16 is a perspective view of a pallet according to yet another preferred embodiment of the invention;

FIG. 17 is a top plan view of a die cut sheet for use in a preferred method of making the pallet of FIG. 13;

FIGS. 18-21 are partial perspective views illustrating a preferred method of making the pallet of FIG. 13;

FIG. 22 is a perspective view of a pallet according to yet another preferred embodiment of the invention;

FIG. 23 is another perspective view of the pallet of FIG. 22;

FIG. 24 is a partial cross sectional view of the pallet of FIG. 23, taken along lines 24-24;

FIG. 25 is a perspective view of a pallet according to yet another preferred embodiment of the invention;

FIG. 26 is a top plan view of a die cut sheet for use in a preferred method of making the pallet of FIG. 23;

FIGS. 27-31 are partial perspective views illustrating a preferred method of making the pallet of FIG. 23;

FIG. 32 is a perspective view of a pallet according to yet another preferred embodiment of the invention; and

FIG. 33 is a perspective view of a pallet according to yet another preferred embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS AND BEST MODE

A pallet according to a preferred embodiment of the invention is illustrated in FIGS. 1-4, and shown generally at reference numeral 10. The pallet 10 includes a platform 12 with a plurality of circular openings 14 and a leg 22 positioned within each of the openings 14. The legs 22 are preferably conical and positioned such that the larger diameter end 24 of each leg 22 is connected to the platform 12, and the smaller diameter end 26 rests on the floor.
The platform 12 is formed of double wall corrugated paper having a thickness of 6.5 mm, with nine openings 14 for receiving the legs 22. Each opening 14 has a diameter of 95 mm.
As shown in FIGS. 3 and 4, the legs 22 are conical and open at both ends 24, 26, and are tapered at an angle of about 10 degrees. The legs 22 are made of 3-3.5 laps of 380-400 g/sqm paper having a thickness of 630 microns, and have a length of 116 mm. The inner diameter of the large diameter end 24 is 100 mm, and the inner diameter of the small diameter end 26 is 59 mm. The large diameter end 24 has a radius pattern 294, and the small diameter end 26 has a radius pattern of 177. Each leg 22 preferably weighs 40.7 grams. The pallet 10 is thus conducive to recycling and disposal as it can be made completely of paper.
An adhesive, such as polyvinyl acetate (PVA) glue is sprayed or spread around the outer rim of the large diameter end 24 of the legs 22. The legs 22 are then pushed down through the openings 14. As shown in FIG. 5, the platform 12 includes foldable flap sections 16 proximate the openings 14. The openings 14 are sized such that the flap sections 16 fold downwardly and engage the large diameter end 24 of the legs 22 when the legs 22 are pushed through the openings 14. The adhesive on the legs 22 adheres to the flap sections 16 of the platform 12. Alternatively, the adhesive can be put on the flap sections 16 prior to positioning the legs 22 within the openings 14.
As shown in FIGS. 6 and 7, each leg 22 has a bull nose 28 formed at the small diameter end 26. The bull nose 28 is formed by folding a portion of the leg 22 inwardly so that the bull nose 28 extends around the circumference of the inner wall surface of the leg 22.
As shown in FIGS. 8-10, the pallet 10 can be nested within another like pallet 10′, and vice versa. As shown in FIGS. 9 and 10, the bull nose 28 of the first pallet 10 provides a stop for the leg 22′ of a second pallet 10′ that is being nested within the first pallet 10. As such, the second pallet 10′ is prevented from sliding all the way to the end of the leg 22 of the first pallet 10, thereby preventing the two pallets 10, 10′ from getting stuck too tightly together while in storage. This facilitates separation of the two pallets 10, 10′ when it is desired to next use the pallets 10, 10′ for material transport. Additional pallets can be nested, such as is illustrated in FIG. 8, which shows the nesting of four pallets 10.
In addition to facilitating separation of nested pallets 10, 10′, the bull nose 28 also adds radial and axial strength to the leg 22, which compensates for the absence of a bottom panel in the leg 22, enabling the pallet 10 to withstand heavier loads. Preferably, the pallet 10 can support an evenly distributed mass of about 600 kg. Furthermore, the bull nose 28 provides a smooth surface at the bottom of the leg 22 that facilitates sliding movement of the pallet 10 on a supporting surface such as the ground or floor.
A pallet according to another preferred embodiment of the invention is illustrated in FIGS. 11-12, and shown generally at reference numeral 100. The pallet 100 is similar in construction to the previously described pallet 10, except that each leg 122 of the pallet 100 has two cones 122 a, 122 b. This construction adds strength to the legs 122 and enables the pallet 100 to withstand heavier loads.
Each cone 122 a, 122 b has flared portions 123 a, 123 b, respectively, extending outward from the large diameter ends 124 a, 124 b of the cones 122 a, 122 b. An adhesive, such as polyvinyl acetate (PVA) glue, is sprayed or spread onto the flared portion 123 a of the outer cone 122 a, which is then pressed on the lower surface of the platform 112 of the pallet 100. Adhesive is sprayed at the inner surface of the small diameter end 126 a of the outer cone 122 a within the area between the bull nose 128 a and the sidewall of the cone 122 a. Adhesive is placed on the flared portion 123 b of the inner cone 122 b, and the inner cone 122 b is positioned on top of the outer cone 122 a, such that the flared portion 123 b of the inner cone 122 b rests on the upper surface of the platform 112. The small diameter end 126 b of the inner cone 122 b contacts the adhesive in the crevice of the bull nose 128 a of the outer cone 122 a to adhere the outer cone 122 a and the inner cone 122 b together. The inner cone 122 b does not have a bull nose.
As shown in FIG. 11, the outer cone 122 a is sloped at an angle a relative to the vertical axis that is greater than the sloped angle β of the inner cone 122 b. Preferably, the angle α of the outer cone 122 a is about ten degrees, and the angle β of the inner cone 122 b is about eight degrees. This results in an area between the flared portions 123 a, 123 b of the outer cone 122 a and inner cone 122 b, respectively, within which a portion 114 of the platform 112 can be sandwiched.
As shown in FIG. 11A, the leg 122′ of a second pallet 100′ can be nested within the leg 122 of the pallet 100, and since the outer cone 122 a′ of leg 122′ of the nesting pallet 100′ has a slightly greater angle α than the angle β of the inner cone 122 b of the receiving pallet 100, the nesting pallet 100′ is not allowed to descend all the way to the very bottom of the leg 122 of the receiving pallet 100. This prevents the two pallets 100, 100′ from becoming stuck to tightly together and facilitates easy separation of the two pallets 100, 100′.
The pallet 100 can be made of corrugated paper, or other suitable material including moisture resistant paper board. It should be noted that the term “paper” as used throughout this application refers generally to all kinds of paper, including cardboard.
A pallet according to another preferred embodiment of the invention is illustrated in FIGS. 13 and 14, and shown generally at reference numeral 200. The pallet 200 includes a platform 212 and three leg members 201, 202, 203.
The platform 212 has a top side 213 for carrying objects, and an under side 214 opposite the top side 213. While the platform 212 is preferably rectangular as shown in FIGS. 13 and 14, it can be a variety of suitable shapes. Three leg members 201, 202, 203 are positioned on the under side 214 of the platform in substantially parallel relation to each other. The first leg member 201 is positioned at one end 215 of the platform 212, and the second leg member 202 is positioned at the opposite end 216 of the platform 212. The third leg member 203 is positioned intermediate the first and second leg members 201, 202 at approximately the center of the platform 212. The leg members 201, 202, 203 are substantially parallel with each other.
As shown in FIG. 13, each of the three leg members 201, 202, 203 are rectangular, and extend across the width of the platform 212. As such, the first and second leg members 201, 202 are coextensive with the first and second ends 215, 216, respectively, of the platform 212.
The first and second leg members 201, 202 each have four walls 201 a-d, 202 a-d, respectively. The third leg member 203 has a total of five walls 203 a-e. While the leg members 201, 202, 203 are preferably rectangular, they can be a variety of shapes, such as conical, triangular or other polygonal shape. In addition, the number of leg members can be varied.
The first walls 201 a, 202 a, 203 a of the leg members 201, 202, 203 lie flat on the under side 214 of the platform 212. The second walls 201 b, 202 b, 203 b extend perpendicularly from the first walls 201 a, 202 a, 203 a and the third walls 201 c, 202 c, 203 c extend perpendicularly from the second walls 201 b, 202 b, 203 b. The fourth walls 201 d, 202 d, 203 d extend perpendicularly from the third walls 201 c, 202 c, 203 c back toward the underside 214 of the platform 212. The fifth wall 203 e of the third leg member 203 extends perpendicularly from the fourth wall 203 d and lies parallel to and flat on the first wall 203 a.
Each of the leg members 201, 202, 203 can have a pair of rectangular openings 205 formed in the second and fourth walls 201 b, 201 d, 202 b, 202 d, 203 b, 203 d of the leg members 201, 202, 203 and aligned on a horizontal axis that is substantially parallel with the platform 212. As such, fork-lift forks can be inserted through the openings 205 to engage and lift the pallet 200. Furthermore, the pallet 200 can be accessed by fork-lift forks from all four sides of the pallet by either inserting the fork-lift forks through the openings 205 in the leg members 201, 202, 203, or by insertion of forks in the space 221 between the first and third leg members and the space 223 between second and third leg members.
Each of the leg members 201, 202, 203 can have a plurality of openings 206 formed on the third wall 201 c, 202 c, 203 c of the leg members 201, 202, 203. A support member, such as a conical paper tube 207, can be positioned within each of the openings 206. The tubes 207 are positioned within the openings 206 of the leg members 201, 202, 203 such that the tubes 207 reside in perpendicular relation to the platform 212, as shown in FIG. 15. The tubes 207 provide added strength and stability to the leg members 201, 202, 203 to enable the pallet 200 to carry heavier loads.
The leg members 201, 202, 203 can be positioned directly on a ground surface and thereby support the platform 212 above the ground surface. Alternatively, the leg members 201, 202, 203 can be mounted on a substantially flat base member 220, as shown in FIG. 16. The base member 230 can be positioned on a ground surface.
A preferred method of making the pallet 200 is illustrated in FIGS. 17-21. A blank sheet of material, such as a paper die cut sheet 222, is provided as shown in FIG. 17. Four fold lines 251, 252, 253, 254 are formed at one end 215 of the sheet 222, and four fold lines 261, 262, 263, 264 are formed at the opposite end 216 of the sheet. Perforated sections 225 are positioned between the first and second fold lines 251, 261, 252, 262, and between the third fold lines 253, 263 and fourth fold lines 254, 264 of the sheet 222. A first plurality of linearly aligned circular openings 206 a are formed between the first and second ends 215, 216 of the sheet 222 and the first fold lines 251, 261, respectively, of the sheet 222. A second plurality of linearly aligned circular openings 206 b are formed between the second fold lines 252, 262 and the third fold lines 253, 263 of the sheet 222.
As shown in FIG. 18, the bottom of the support tubes 207 are positioned within circular openings 206 b on the sheet 222. The first end of the 215 of the sheet 222 is folded over at ninety degree angles at the first and second fold lines 251, 252 such that the top of the support tubes 207 are positioned within the circular openings 206 a, as shown in FIG. 19. The support tubes 207 have a diameter slightly less than the diameter of the openings 206 a, 206 b such that the tubes 207 are held in place within the openings 206 a, 206 b by frictional engagement. The sheet 222 is folded at ninety degree angles at the third and fourth fold lines 253, 254 to form the rectangular leg member 201 having four walls 201 a-d, shown in FIG. 21. An adhesive can be applied to the sheet 222 to attach wall 201 a thereto. Alternatively, other suitable attachment means can be employed to hold the leg member 201, such as staples, nails or other fasteners. The second leg member 202 is made in the same manner as the first leg member 201, and therefore the process is not described again here.
As shown in FIG. 17, the sheet 222 has two pairs of notches 226 formed at opposite ends of the sheet 222 between the third fold lines 253, 263 and the fourth fold lines 254, 264. When the sides 215, 216 of the sheet 222 are folded to form the leg members 201, 202 as described above, the notches 226 are positioned at the four corners of the pallet 200 on the fourth walls 201 d, 202 d of the leg members 201, 202, respectively, as shown in FIG. 13. These notches 226 provide an area for receiving and holding a wrapping material, such as polyvinylidene chloride or other plastic wrap, that is to be wrapped around the pallet 200 and the objects being carried on the pallet 200.
The third leg member 203 is a separate piece that can be attached at the center for the sheet 222 between the first end 215 and second end 216. As shown in FIG. 17, the sheet 222 has two notches 228 located at opposite sides of the center of the sheet 222. The third leg member 203 likewise has notches 208 at opposite ends formed in the center of the first and fifth walls 203 a, 203 e. As such, proper positioning of the third leg member 203 on the sheet 222 is readily obtained by aligning the notches 208 of the leg member 203 with the notches 228 of the sheet 222, as shown in FIG. 13 and 14. The third leg member 203 can be held in place on the sheet 222 by an adhesive placed on the first wall 203 a of the leg member 203 or the sheet 222. Alternatively, other attachment means can be employed such as staples, nails or other fasteners.
When the first and second leg members 201, 202 have been formed, the perforated sections 225 can be partially detached therefrom to form flaps that can be folded inwardly into the leg members 201, 202 to form the openings 205, shown in FIG. 13. The flap sections can be held within the leg members 201, 202 by frictional engagement with the first walls 201 a, 202 a and third walls 201 c, 202 c of the leg members 201, 202, respectively.
A pallet according to yet another preferred embodiment of the invention is illustrated in FIGS. 22 and 23, and shown generally at reference numeral 300. The pallet 300 includes a platform 312 and three leg members 301, 302, 303.
The platform 312 has a top side 313, shown in FIG. 23, for carrying objects thereon, and an under side 314, shown in FIG. 22, opposite the top side 313. While the platform 312 is preferably rectangular, it can be a variety of suitable shapes. Three leg members 301, 302, 303 are positioned on the under side 314 of the platform in substantially parallel relation to each other. The first leg member 301 is positioned proximate one end 315 of the platform 312, and the second leg member 302 is positioned proximate the opposite end 316 of the platform 312. The third leg member 303 is positioned intermediate the first and second leg members 301, 302 at approximately the center of the platform 312. The leg members 301, 302, 303 are substantially parallel with each other.
Each of the three leg members 301, 302, 303 are rectangular, and extend across the width of the platform 312, as shown in FIG. 22. The first and second leg members 301, 302 each have four walls 301 a-d, 302 a-d, respectively. The third leg member 303 has a total of five walls 303 a-e. While the leg members 301, 302, 303 are preferably rectangular, they can be a variety of shapes, such as conical, triangular or other polygonal shape. In addition, the number of leg members can be varied.
The first walls 301 a, 302 a, 303 a of the leg members 301, 302, 303 lie flat on the under side 314 of the platform 312. The second walls 301 b, 302 b, 303 b extend perpendicularly from the first walls 301 a, 302 a, 303 a and the third walls 301 c, 302 c, 303 c extend perpendicularly from the second walls 301 b, 302 b, 303 b. The fourth walls 301 d, 302 d, 303 d extend perpendicularly from the third walls 301 c, 302 c, 303 c back toward the underside 314 of the platform 312, as shown in FIG. 22. The fifth wall 303 e of the third leg member 303 extends perpendicularly from the fourth wall 303 d and lies parallel to and flat on the first wall 303 a.
The platform 312 includes wing sections 315 a, 316 a at opposite ends 315, 316, respectively, as shown in FIGS. 22 and 23. As shown in FIG. 22, the wing sections 315 a, 316 a extend outward perpendicularly from the fourth walls 301 d, 302 d of the first and second leg members 301, 302, respectively.
Each of the leg members 301, 302, 303 can have a plurality of openings 306 formed on the third wall 301 c, 302 c, 303 c of the leg members 301, 302, 303. A support member, such as conical paper tubes 307, can be positioned within the openings 306. The tubes 307 are positioned within the openings 306 of the leg members 3011 302, 303 such that the tubes 307 reside in perpendicular relation to the platform 312, as shown in FIG. 24. The tubes 307 provide added strength and stability to the leg members 301, 302, 303 to enable the pallet 300 to carry heavier loads.
The leg members 301, 302, 303 can be positioned directly on a ground surface and thereby support the platform 312 above the ground surface. Alternatively, the leg members 301, 302, 303 can be mounted on a substantially flat base member 330, as shown in FIG. 25. The base member 330 can be attached to the leg members 301, 302, 303 using an adhesive or other attachment means, such as staples, nails or other fasteners. The base member 330 can be positioned on a ground surface, and can include openings 336, which are shaped and sized to receive a pallet jack.
A preferred method of making the pallet 300 is illustrated in FIGS. 26-31. A blank sheet of material, such as a paper die cut sheet 322, is provided as shown in FIG. 26. Six fold lines 351, 352, 353, 354, 355, 356 are formed at one end 315 of the sheet 322, and six fold lines 361, 362, 363, 364, 365, 366 are formed at the opposite end 316 of the sheet 322. A first plurality of linearly aligned circular openings 306 a are formed between the first and second ends 315, 316 of the sheet 322 and the first fold lines 351, 361, respectively, of the sheet 322. A second plurality of linearly aligned circular openings 306 b are formed between the second fold lines 352, 362 and the third fold lines 353, 363 of the sheet 322.
As shown in FIG. 27, the bottom of the support tubes 307 are positioned within circular openings 306 b on the sheet 322. The first end 315 of the sheet 322 is folded over at ninety degree angles at the first and second fold lines 351, 352 such that the top of the support tubes 307 are positioned within the circular openings 306 a, as shown in FIG. 28. The support tubes 307 have a diameter slightly less than the diameter of the openings 306 a, 306 b such that the tubes 307 are held in place within the openings 306 a, 306 b by frictional engagement. As shown in FIG. 30, the sheet 322 is folded at ninety degree angles at the third and fourth fold lines 353, 354 to form the rectangular leg member 301 having four walls 301 a-d, shown in FIGS. 31. The sheet is folded at ninety degree angles at the fifth and sixth fold lines 355, 356 to form a side edge 318 that joins the top side 313 and under side 314 of the platform 322.
As shown in FIG. 26, the distance between the end 315 of the platform 322 and the first fold line 351 is greater than the distance between the first and second fold lines 351, 352, second and third fold lines 352, 353, and third and fourth fold lines 353, 354. The relatively greater distance between the end 315 of the platform 322 and the first fold line 351 result in the formation of the wing section 315 a extending outward from the leg member 301.
An adhesive can be applied to the sheet 322 to attach wall 301 a thereto, as shown in FIG. 29. Alternatively, other suitable attachment means can be employed to hold the leg member 301 to the platform 322, such as staples, nails or other fasteners. The second leg member 302 is made in the same manner as the first leg member 301, and therefore the process is not described again here.
The third leg member 303 is a separate piece that can be attached at the center for the sheet 322 between the first end 315 and second end 316 of the platform 322. The third leg member 303 can be held in place on the sheet 322 by an adhesive 340 placed on the first wall 303a of the leg member 303 or the sheet 322. Alternatively, other attachment means can be employed such as staples, nails or other fasteners.
Yet another alternative embodiment of the invention is illustrated in FIG. 32, and shown generally at reference numeral 400. The pallet 400 includes a platform 412 and two leg members 401, 402, and is similar to the previously described pallet 200, but does not have a third leg member between the first and second leg members 401, 402. One advantage of pallet 400 is that it can be made entirely of a single sheet of paper or other suitable material.
A pallet according to yet another embodiment of the invention is illustrated in FIG. 33, and shown generally at reference numeral 500. The pallet 500 includes a platform 512, and two elongate rectangular leg members 501, 502. A plurality of conical leg members 522 are positioned between the two elongate rectangular leg members 501, 502, and are arranged in a line that is parallel with the rectangular leg members 501, 502. Although leg members 522 are conical, the leg members 522 can be other shapes such as tubular or square.
A pallet and methods for making same are disclosed above. Various embodiments of the invention can be made without departing from its scope. Furthermore, the foregoing description of the preferred embodiments of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation—the invention being defined by the claims.

Claims

1. A pallet comprising:

(a) a platform having a plurality of openings for carrying an object thereon;

(b) a plurality of legs attached to the platform for supporting the platform above a surface, wherein each of the legs is positioned in a respective one of each of the platform openings and comprises:

(i) a cone having an upper end proximate the platform and a lower end for resting on the surface,

(ii) the upper end having a diameter greater than a diameter of the lower end whereby a second like pallet can be nested within the first pallet, and

(iii) and further wherein the leg includes a bull nose positioned proximate the lower end for providing a stop for the second like pallet nested within the first pallet to facilitate separation of the second pallet from the first pallet.

2. A pallet according to claim 1, wherein the platform comprises a plurality of foldable sections positioned proximate the platform openings for providing a surface area contacting the legs, wherein the legs are attached to the platform by an adhesive contacting the legs and the surface area of the foldable sections.

3. A pallet comprising:

(a) a platform having an upper surface, a lower surface, and a plurality of openings therethrough; and

(b) a plurality of legs attached to the platform for supporting the platform above a surface, wherein each of the plurality of legs is positioned in a respective one of the platform openings and comprises:

(i) an outer cone having an upper end proximate the platform and a lower end for positioning on the surface, the upper end defining a diameter greater than a diameter defined by the lower end, and

(ii) an inner cone positioned within the outer cone and having an upper end proximate the platform and a lower end opposite the upper end, the upper end defining a diameter greater than a diameter defined by the lower end.

4. A pallet according to claim 3, wherein each of the plurality of legs includes:

(a) a first flared section proximate the upper end of the inner cone and attached to the upper surface of the platform;

(b) a second flared section proximate the upper end of the outer cone and attached to the lower surface of the platform; and

(c) wherein an area of the platform defining each of the plurality of openings is sandwiched between the first flared section and the second flared section of each of the legs.

5. A pallet according to claim 3, wherein the lower end of the outer cone of each of the legs includes a bull nose defining an area that receives the lower section of the inner cone.

6. A pallet according to claim 3, wherein the pallet is made of paper.

7. A pallet according to claim 3, wherein the inner cone is sloped at an angle less than the outer cone.

8. A pallet according to claim 7, wherein the inner cone is sloped at an angle of about eight degrees, and the outer cone is sloped at an angle of about ten degrees.

9. A pallet according to claim 7, wherein the lower end of the outer cone of each of the legs includes a bull nose defining an area that receives the lower end of the inner cone.

10. A pallet according to claim 7, wherein an outer surface of the inner cone is attached to an inner surface of the outer cone by an adhesive.