Pallet and load packaging method

Abstract
A pallet includes a loading member made from paper onto which a load is loaded; leg members made from paper which are fixed to the loading member and, as well as supporting the loading member when a load is loaded on the loading member, form an insert body receiving member into which is inserted an insert body used during transportation; and a base member made from paper which is fixed to the opposite side of the leg members to the loading member. A load is loaded onto the loading member of this type of pallet and is intermediately packaged with intermediate packaging material in a process including a load loading step for loading the load onto the loading member; and a fastening step for fastening the intermediate packaging material with which the load was intermediately packaged in the intermediate packaging step to the loading member.
Description




BACKGROUND OF THE INVENTION




1. Field of the Invention




The present invention relates to a pallet on which a load is loaded and then transported or stored and a load packaging method for loading and packaging a load loaded on the pallet.




2. Description of the Related Art




A conventional pallet used for the transport and storage etc. of goods is normally a general purpose item made from wood or metal and formed without consideration given to the shape of the load to be loaded on the pallet.




The transport and storage of photosensitive printing plates will be described as an example. When a large quantity of photosensitive printing plates are packaged (for example, 250˜1500 plates per one package) and transported, the photosensitive printing plates which are manufactured in a factory are placed in stacks of a predetermined number and intermediately packaged. The intermediately packaged photosensitive printing plates are then stacked on general use pallets made of wood or metal and externally packaged, and are then transported or stored. In some cases, the photosensitive printing plates are also stacked directly on the pallets and then externally packaged before being transported or stored.




However, general use pallets made of wood or metal are expensive due to the material costs and the labor required for their manufacture. Moreover, these pallets are heavy and difficult to handle during transport or storage. Furthermore, disposal of the wood or metal forming the pallet is difficult and pallets are sometimes left to accumulate at their destination after being transported.




In addition, because general use pallets are used which are made without consideration given to the shape of the load, positioning and fastening of the load when loading the pallets have been difficult.




On the other hand, when a small quantity of photosensitive printing plates are packaged (for example, 10˜100 plates per package) and transported, units of stacked and intermediately packaged photosensitive printing plates are further placed in corrugated fiberboard boxes, which are then packaged and transported etc.




However, if corrugated fiberboard boxes are used, it is necessary to perform the time-consuming task of opening each corrugated fiberboard box one by one when the photosensitive printing plates are to be used. Moreover, because the empty corrugated fiberboard boxes end up as waste material at their destination, a great deal of waste materials are generated particularly after a large quantity of photosensitive printing plates have been transported.




SUMMARY OF THE INVENTION




In consideration of the above, the aim of the present invention is to provide a pallet which is inexpensive and easy to handle during transport or storage and a load packaging method in which a load can be easily loaded on this pallet and packaged.




The first aspect of the present invention is a pallet comprising: a loading member made from paper onto which a load is loaded; a leg member made from paper which is fastened to the loading member and, as well as supporting the loading member when a load is loaded on the loading member, forms an insert body receiving member into which is inserted an insert body used during transportation; and a base member made from paper which is fixed to the opposite side of the leg member to the loading member.




Accordingly, when a load has been loaded onto the loading member, the insert body is inserted into the insert body receiving member which is formed by the leg member, and the pallet and load are able to be transported. The insert body named here may be any member provided that the pallet becomes transportable by inserting the insert body into the insert body receiving member. An example of the insert body is the forks of a fork lift, however, the insert body is not limited to this and other examples include an elongated bar which may be inserted as an insert body into the insert body receiving member and the portion of the bar which protrudes from the pallet lifted and pushed sideways, thus allowing the pallet and load to be transported.




Because the loading member, the leg member, and the base member which form the pallet are all made from paper, the pallet is lighter than comparable pallets made from metal or resin, and handling the pallets during transport or storage is easier. Furthermore, used pallets are easily disposed of at their destination. Naturally, when the pallets are still capable of being reused (i.e. when their strength and shape as pallets are preserved), they may be reused. Moreover, even when they are not capable of being reused, because the pallets are made from paper, they can be easily recycled. In addition, by manufacturing the pallets out of paper, the manufacturing costs can be kept down.




The paper which is used as the material for the loading member, the leg member, and the base member, is not particularly limited, and any material which has a certain strength and can maintain the shape of the pallet and support the weight of the load is acceptable. For example, general corrugated fiberboard, honeycomb structure materials made from paper, cardboard, Kraft paper and the like may be used. Moreover, the general corrugated fiberboard, honeycomb structure materials made from paper, cardboard, Kraft paper and the like may be laminated to produce an even stronger material which can also be used. Each of the loading member, the leg member, and the base member may also be made out of different types of paper.




Because the leg member is fastened to the loading member, manufacturing of the pallet is simplified. There is no particular limit as to the number of leg members. For example, a plurality of leg members may be provided with predetermined gaps formed therebetween which gaps act as insert body receiving members. Thus insert body receiving members can be provided by a simple structure.




When a plurality of leg members are provided, the plurality of leg members are fixed from two sides by the loading member and the base member and are thus able to more securely support the loading member. Moreover, when a plurality of pallets each with a load loaded thereon are stacked on top of each other, the base plate portion directly above the top surface of a load makes surface contact with the top surface of the load so that the weight on the load is distributed and the load is not damaged or deformed. This enables handling to be simplified.




In the present invention, the loading member is preferably constructed by superposing more sheets of paper than are used to construct the base.




This causes the strength of the loading member to be greater than that of the base member. Accordingly, when a pallet with a load loaded thereon is lifted or moved, deformation of the loading member and deformation or shifting of the load can be prevented.




In the present invention, the loading member is preferably constructed by superposing a plurality of sheets of paper in such a manner that the grain of at least one sheet of the paper forming the loading member intersects the direction of the grain of the other sheets of paper forming the loading member.




By making the direction of the grain of the sheets of paper forming the loading member intersect in this way, unevenness in the strength of the loading member depending on the direction can be reduced. Accordingly, when, for example, the insert body is inserted for transporting, a fixed level of strength can be maintained no matter which direction the insert body is inserted from. Thus, deformation of the loading member and deformation or shifting of the load can be prevented.




In the present invention, the leg member is preferably hollow.




Accordingly, the leg member is light in weight which simplifies handling during transporting and storage. Moreover, because the actual amount of paper needed to construct the leg member is reduced, the leg member can be formed at a lower cost allowing the pallet as a whole to be manufactured cheaply.




Note that the leg member is not particularly limited to a hollow leg member. For example, a hollow leg portion may be formed by stacking a plurality of sheets of paper side on to each other to form a side wall of a leg member and fixing a plurality of the side walls in a predetermined layout. However, a single sheet of paper may be bent and rolled up in a coil to form a cylindrical shape (a round cylinder, four sided cylinder, or three sided cylinder). By forming the leg member from a single sheet of paper in this way, the number of parts is reduced and the manufacturing of the leg is simplified.




In the present invention, the loading member is preferably provided with an extending portion which extends outwards further than the load which is loaded onto the loading member.




Because of this extending portion, even if another member strikes against the pallet during transport or storage, this other member strikes against the extending portion and not against the load, thus allowing the load to be protected and simplifying handling.




In the present invention, the loading member preferably has a step portion provided with a peripheral portion which is flush with the side surfaces of the load when a load is loaded on the loading member.




Accordingly, when a load is loaded onto the step portion, the side surfaces of the load are flush with the peripheral portion of the step portion. An intermediate packaging material is placed in surface contact with the side surfaces of the load and the peripheral portion of the step portion thus intermediately packaging the load and the step portion as a single body. This allows the intermediate packaging material to be fixed by the step portion and the load to then be fixed by the intermediate packaging material. Because this structure prevents the load from shifting the position on the loading member, handling during transporting and storage are simplified.




In the present invention, the extending portion is preferably formed so as to bend the loading member towards the load at a position further from the outer edge portion of the load loaded onto the loading member than the thickness of the intermediate packaging material with which the load is intermediately packaged.




In this pallet, the bend of the extending portion may be made in advance before the load is loaded on the loading member or may be made after the load has been loaded and packaged with the intermediate packaging material.




If the bend is made in advance, the load and intermediate packaging can be easily positioned on the loading member.




If the bend is made after the intermediate packaging has been applied, because it is sufficient if the bend is made along the outer edge of the load (or intermediate packaging), the task is simplified. It is also possible to apply the intermediate packaging, then the external packaging, then to bend the extending member from outside the external packaging.




In whichever case, the bent portion after being bent contacts the load and the load is unable to shift position on the loading member, therefore, handling during transporting and storage is simplified.




Note that the position where the loading member is bent is not limited provided it is at a position outside the thickness of the intermediate packaging material. For example, the bend may be made at a position outside the combined thickness of the intermediate packaging material and the external packaging material.




In the present invention, a housing portion is preferably formed in the loading member which houses a transporting member for transporting the load, and is able to allow the transporting member to be removed when the load has been loaded on the loading member by the transporting member.




The transporting member mentioned here may be any member provided that it is able to transport a load before that load is loaded on a loading member. Examples include the forks of a forklift and an accumulating arm which accumulates a load on the load production line and transports it.




When the load is supported by the transporting member, transported to the loading member and placed on the loading member, the transporting member is housed in the housing portion. Therefore, the transporting member does not get caught between the loading member and the load. Once the load is loaded on the loading member, the transporting member can be removed from the housing portion thus simplifying the task of loading the load onto the loading member.




The second aspect of the present invention is a load packaging method in which a load is loaded onto a loading member of a pallet and is intermediately packaged with intermediate packaging material comprising the following steps: a load loading step for loading the load onto the loading member; an intermediate packaging step for intermediately packaging the top surface and side surfaces of the load loaded onto the loading member with the intermediate packaging material; and a fastening step for fastening the intermediate packaging material with which the load was intermediately packaged in the intermediate packaging step to the loading member.




In this way, after the load has been loaded on the loading member, the load can be easily intermediately packaged simply by intermediately packaging the load with the intermediate packaging material and fastening this intermediate packaging material to the loading member. There is no particular limitation as to the intermediate packaging material, however, by using paper with excellent moisture proof properties or paper with excellent light proof properties, the load can be given general protection from moisture and light.




There is no particular limitation either as to the fastening means for fastening the intermediate packaging material to the loading member and adhesive tape or bond, for example, may be used. However, using adhesive tape makes the adhering task easier.




In the present invention, before the step to load a load on a loading member, a laying step is preferably performed to lay intermediate packaging material, which is substantially the same shape as the loading member, on the loading member.




In this way, by laying intermediate packaging material on the loading member, intermediate packaging material is disposed on the bottom surface of the load as well. Therefore, when moisture proof and light proof paper are used for the intermediate packaging material, the ability to protect the load from moisture and light can be increased.




The second aspect of the present invention is a load packaging method for loading a load onto a loading member of a pallet according to the first aspect of the present invention and packaging the load preferably comprising: a laying step for laying a lower intermediate packaging material formed to a larger size than the loading member on the loading member; a lower intermediate packaging step for loading a load onto the lower intermediate packaging material laid in the laying step and for bending upwards portions of the lower intermediate packaging material which extend out beyond the load thus intermediately packaging the bottom surface and a portion of or all of the side surfaces of the load; and a fastening step for intermediately packaging the top surface and side surfaces of the load loaded onto the loading member with an upper intermediate packaging material and fastening the upper intermediate packaging material to the lower intermediate packaging material.




In this way, by laying the lower intermediate packaging material on the loading member, intermediate packaging material is disposed on the bottom surface and side surfaces of the load. Then in the fastening step, by intermediately packaging the top surface and side surfaces of the load with upper intermediate packaging material and fastening this to the lower intermediate packaging material, the external surfaces of the load can be completely intermediately packaged. Therefore, when light proof and water proof paper is used for the intermediate packaging, the ability to protect the load from moisture and light can be increased.




In the load packaging method of the second aspect of the present invention using a pallet of the first aspect of the present invention, preferably, in the step to load the load on the loading member, the side surfaces of the load and the side portions of the step are made flush, and in the intermediate packaging step, the intermediate packaging material is placed in surface contact with both the side surfaces of the load and the side portions of the step.




Accordingly, when the intermediate packaging material is placed in surface contact with the side surfaces of the load and the side portions of the step when both the side surfaces of the load and the side portions of the step are flush with each other, the load and the step can be intermediately packaged as one body. Because the intermediate packaging material is fixed by the step and the load is further fixed by the intermediate packaging material, there is no shifting in the position of the load on the loading member and handling during transport and storage are simplified.




The present invention is a load packaging method using the pallet of the first aspect of the present invention, wherein, preferably, in the laying step, lower intermediate packaging material is laid while the extending portion is not bent, and in the lower intermediate packaging step, the lower intermediate packaging material and the extending portion are bent upwards.




Namely, because the extending portion is bent after the load has been packaged with the intermediate packaging material, the extending portion does not become a hindrance when the load is loaded and the task of loading is simplified.




Note that, in the lower intermediate packaging step, the lower intermediate packaging material may be bent first and the extending portion bent after that. However, the lower intermediate packaging material and the extending portion may be bent as one material. If the two are bent as one, in this way, the number of steps is decreased and the task of bending is simplified.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

is a perspective view showing a pallet according to the first embodiment of the present invention.





FIG. 2

is a perspective view showing a cross section of a portion of a pallet according to the first embodiment of the present invention.





FIG. 3

is a perspective view showing a pallet according to the first embodiment of the present invention and a load unit and intermediate packaging material loaded on this pallet.





FIG. 4

is a perspective view showing a load unit which has been loaded on a pallet according to the first embodiment of the present invention and intermediately packaged using intermediate packaging material.





FIG. 5

is a perspective view showing a load unit which has been loaded on a pallet according to the first embodiment of the present invention and externally packaged.





FIG. 6

is a perspective view showing a load unit which has been loaded on a pallet according to the first embodiment of the present invention and a cover which has been fitted over the external packaging material.





FIG. 7

is a perspective view showing a load unit which has been loaded onto a pallet according to the first embodiment of the present invention and external packaging fastened with a band.





FIG. 8

is a perspective view showing a pallet according to the second embodiment of the present invention.





FIG. 9

is a perspective view showing a pallet according to the second embodiment of the present invention and intermediate packaging material and a load unit loaded onto this pallet.





FIG. 10

is a perspective view showing a pallet according to the third embodiment of the present invention.





FIG. 11

is a perspective view showing a pallet according to the fourth embodiment of the present invention.





FIG. 12

is a perspective view showing a pallet according to the fifth embodiment of the present invention.





FIG. 13

is a perspective view schematically showing a production line for photosensitive printing plates to be loaded onto a pallet of the present invention.











DESCRIPTION OF THE PREFERRED EMBODIMENTS





FIG. 1

shows a pallet


10


according to the first embodiment of the present invention.

FIG. 13

schematically shows a production line


310


for photosensitive printing plates which are to be loaded onto the pallet


10


and then transported, stored, or the like. Note that, in the description below, photosensitive printing plates are used as the example of the load on the pallet


10


, but the present invention may also be applied to heat sensitive printing plates.




A feeding mechanism


312


, a notcher


314


, a slitter


316


, flying shears


318


, and an accumulating apparatus


320


are disposed in that order going from the upstream side (top right side of

FIG. 13

) to the downstream side (bottom left side of

FIG. 13

) of a production line


310


.




Web


322


, in the form of a roll, is fed into the feeding mechanism


312


where a plurality of webs


322


are joined together in sequence to form an elongated web. Backing paper


330


transported from another line is adhered to the web


322


, which is fed out from the feeding mechanism


312


, which proceeds to the notcher


314


.




The notcher


314


makes partial notches including in both ends of the web


322


in the transverse direction thereof, to form so-called ear portions


324


. The web


322


is then trimmed to a predetermined width by a trimming upper blade


326


and a trimming lower blade of the slitter


316


. Because the trimming upper blade


326


and the trimming lower blade


328


of the slitter


316


enter into the ear portions


324


, they are able to move in the transverse direction of the web


322


. Therefore, while continually making cuts, the trimming width of the web


322


(the width cut by the slitter


316


) can be altered.




In this way, the web


322


, which has a predetermined trimming width, is cut to a predetermined length by the flying shears


318


, thus producing a photosensitive printing plate of the desired size.




In the accumulating apparatus


320


, a plurality of photosensitive printing plates, to which is adhered the backing paper


330


, are accumulated (accordingly, the photosensitive printing plates and the backing paper


330


are alternately superposed), thus forming a stack


112


(see

FIG. 3

) of photosensitive printing plates.




When the stack


112


is sent further along the production line


310


, as is shown in

FIG. 3

, a load unit


114


is formed as a single load from one stack


112


or a plurality of stacks


112


loaded onto a single pallet


10


(the examples in

FIGS. 3 and 4

show a load unit


114


formed from four stacks


112


lined up two abreast in both the longitudinal and transverse directions loaded onto a pallet).




As is shown in

FIG. 1

, the pallet


10


is formed from a loading tray


12


, onto which stacks of photosensitive printing plates


112


are loaded, a base plate


14


which is disposed parallel to the loading tray


12


, and a plurality (nine in the present embodiment) of leg portions


16


, which are disposed between the loading tray


12


and the base plate


14


.




As is shown in detail in

FIG. 2

, a loading tray


12


is formed from a plurality of sheets of corrugated fiberboard


18


, formed in the same shape, which are stacked side against side and then bonded using a bonding material such as a general adhesive. In the present embodiment, five sheets of corrugated fiberboard


18


are used to form the loading tray


12


, however, the present invention is not limited to this and, providing that the weight of the load unit


114


(the combined weight of the stacks


112


), which is loaded onto the loading tray


12


, and the weight of the intermediate packaging material


124


and the external packaging material


116


, which are described later, can be supported, then even one sheet of corrugated fiberboard may be used. However, it is preferable that more sheets of corrugated fiberboard are used for the loading tray


12


than for the base plate


14


in order to securely support the weight. Further, it is not absolutely necessary for the shape of the sheets of corrugated fiberboard


18


forming the loading tray


12


to be identical, and the loading tray


12


may be formed from layers of corrugated fiberboard


18


whose shape is only the same every second layer.




As is shown in

FIG. 1

, the width W


1


and length L


1


of the loading tray


12


are each set at a predetermined size so as to be slightly larger than the load unit


114


after the load unit


114


has been packaged with the external packaging material


116


. More specifically, the accumulating apparatus


320


is set so that the width W


1


and length L


1


of the loading tray


12


have the following relation to the width W and length L of the load unit


114


(see

FIG. 3

) and the thickness D of the external packaging


116


(see FIG.


4


):








W


1>


W


+2


D


  (1)










L


1>


L


+2


D


  (2)






Accordingly, as is shown in

FIG. 4

, when the periphery of the load unit


114


loaded on the loading tray


12


is externally packaged with the external packaging material


116


, the vicinity of the outer edge of the loading tray


12


extends beyond the load unit


114


. This extending portion is the extending portion


20


of the present invention. Note that when there is no need to form the extending portion


20


, then the following relationship may be followed:







W


1


=W


+2


D


  (1)′








L


1


=L


+2


D


  (2)′






In

FIG. 2

, the sheets of corrugated fiberboard


18


are layered so that the directions of the waves in the center of each sheet of fiberboard


18


are all running in the same direction. However, the direction of the waves in the center of each sheet of fiberboard is not particularly limited and the sheets of fiberboard may be layered so that, for example, at least one of the sheets of fiberboard


18


has the center waves thereof running in a direction intersecting (which may include the orthogonal direction) the direction of the center waves of the other sheets of fiberboard. By layering the sheets of fiberboard


18


so that the directions of the waves in the center of each sheet intersect each other, there is no weakness in the strength of the loading tray


12


in a particular direction. Moreover, by reducing the directionality of the strength (i.e., unevenness in the directionality) in this way, when the pallet


10


is supported by the forks of a forklift being inserted in the insert body receiving member


22


(described later), the forks are able to be inserted from any direction to support the pallet


10


.




The leg portions


16


are formed in a four cornered spiral shape by bending an elongated sheet of corrugated board


18


at right angles at predetermined positions in a uniform direction. The leg portions


10


as a whole are thus formed into four sided cylinders open at the top and bottom thereof. Note that the shape of the leg portions


16


is not limited to this and may be in a block shape or a long string-like shape. However, using some type of cylindrical shape (there is no particular restriction on the shape of the cylinder and, in addition to the above four sided cylinder, any hollow cylindrical shape such as round cylinders and three sided cylinders may be used) allows the weight to be kept light, due to the hollow center, and the amount of corrugated fiberboard


18


needed to form a leg portion


16


(i.e. the length of the elongated corrugated fiberboard


18


before it is formed into the leg portion


16


) to be reduced. Moreover, this type of cylindrical shape enables the strength required to support the weight of the stack of photosensitive printing plates


112


via the loading tray


12


to be maintained.




Even if the leg portions


16


are formed using a four sided cylinder structure, the cylinder is not limited to one formed in the above spiral shape, however, forming the cylinder in a spiral shape means that the leg portion


16


can be formed from a single piece of corrugated fiberboard


18


which reduces the number of parts and simplifies the forming of the leg portion


16


.




The leg portion


16


are disposed with a predetermined spacing between each leg portion. An insertion hole (insertion body receiving member)


22


is formed between adjacent leg members


16


, the loading tray


12


and the base plate


14


. This insertion hole


22


is formed in a predetermined shape so that a fork of the forklift for transporting the pallet


10


can be inserted therein.




The base plate


14


is formed from corrugated fiberboard in substantially the same shape as the corrugated fiberboard forming the loading tray


12


. There are no particular restrictions on the number of sheets of corrugated fiberboard forming the base plate


14


and a plurality of sheets may be stacked side to side in layers, however, the base plate


14


of the present embodiment is formed from one sheet of corrugated fiberboard.




The loading tray


12


, is bonded to the leg portions


16


and the leg portions


16


to the base plate


14


by a bonding agent such as a general adhesive so that there is no inadvertent separation or shifting in the positions between the portions. Moreover, the leg portions


16


are fixed on two sides by the loading tray


12


and the base plate


14


and are also connected to each other via the loading tray


12


and base plate


14


so that the loading tray


12


can be reliably supported when a load is loaded thereon.




Next an explanation will be given of the method used for loading and packaging (intermediate and external packaging) stacks of photosensitive printing plates


112


on a pallet


10


according to the first embodiment, and of the working of the pallet


10


.




Firstly, a pallet


10


is set at a predetermined position in the accumulating apparatus


320


on the photosensitive printing plate production line


310


shown in FIG.


13


. The outline of the pallet


10


is larger than the outline of a load unit


114


formed from stacks of photosensitive printing plates


112


, however, because the difference in size is slight, the pallet can be set directly without having to alter the structure or shape of the accumulating apparatus


320


.




Next, as is shown in

FIG. 3

, lower intermediate packaging material


124


A is placed substantially centrally over the top surface of the loading tray


12


. This lower intermediate packaging material


124


A is made from moisture proof and light proof paper and is larger than the bottom surface of the load unit


114


. The lower intermediate packaging material


124


A may be simply placed on top of the loading tray


12


, however, it is preferable if it is fastened thereto by an adhesive agent or by adhesive tape.




When the production line


310


is set in operation, stacks of photosensitive printing plates


112


are loaded directly onto the pallet


10


to form a load unit


114


. Because the lower intermediate packaging material


124


A is larger than the bottom surface of the load unit


114


the outer edge portions of the lower intermediate packaging material


124


A extend beyond the load unit


114


. Because the load unit


114


is formed in this way by loading stacks of photosensitive printing plates


112


directly onto the pallet


10


, there is no need to temporarily accumulate the stacks of photosensitive printing plates


112


from the accumulating apparatus on a separate pallet and then load them again onto the pallet


10


, which allows the task of accumulation to be performed more efficiently.




After a load unit


114


has been formed by loading stacks


112


onto the loading tray


12


, the extending portion of the lower intermediate packaging material


124


A is bent up against the load unit


114


and is placed in surface contact with the side surfaces (the front surface


114


A, the rear surface


114


B, and the side surfaces


114


C) of the load unit


114


. Thus the bottom surface and a portion of the side surfaces (or all of the side surfaces) of the load unit


114


are intermediately packaged.




Upper intermediate packaging material


124


B is placed substantially centrally on the top surface of the load unit


114


. This upper intermediate packaging material


124


B is made from the same paper material as the lower intermediate packaging material


124


A, and is of a predetermined size so that, when the portion extending out past the top surface of the load unit


114


is bent down to be in surface contact with the side surfaces of the load unit


114


, it partially overlaps the lower intermediate packaging material


124


A.




As is shown in

FIG. 4

, after the upper intermediate packaging material


124


B has been bent down, the overlapping portions of the upper intermediate packaging material


124


A and lower intermediate packaging material


124


B are fastened around the entire periphery of the load unit


114


by adhesive tape


126


. Thus, the load unit


114


is completely wrapped in the intermediate packaging material


124


(i.e. the upper intermediate packaging material


124


A and lower intermediate packaging material


124


B) and is made completely moisture proof and light proof. Namely, in view of the nature of a photosensitive printing plate, it is necessary to shield it from light because it is sensitive to light in the visible wavelength band. Moreover, even if heat sensitive printing plates are used instead of photosensitive printing plates, because changes in the sensitivity thereof may occur due to deterioration of the heat sensitive layer or reaction progression caused by the thermal energy of light striking the heat sensitive printing plates, it is preferable that appropriate light shading is carried out. Moreover, in conditions of high humidity, problems such as the photosensitive layer or heat sensitive layer of the respective printing plates deteriorating and the sensitivity changing, or the backing paper


330


adhering to adjacent printing plates easily occur, therefore it is necessary to moisture proof the plates. Accordingly, as described above, because the photosensitive printing plates (or heat sensitive printing plates) are made completely moisture proof and light proof by the intermediate packaging material


124


, all the above problems are solved. Note that either the lower intermediate packaging material


124


A or the upper intermediate packaging material


124


B may be on the outside at the point where the two materials overlap.




In this way, the load unit


114


is intermediately packaged with the intermediate packaging material


124


, and with the load unit


114


in a completely moisture proof state, the forks of a forklift are inserted into the insertion holes


22


formed between leg portions


16


of the pallet


10


, then with the stacks


112


loaded on the loading tray


12


, the pallet


10


is removed from the production line


310


. At this time, if the loading tray


12


has been constructed so that the direction of the waves inside at least one sheet of corrugated fiberboard


18


intersect the direction of the waves inside the other sheets of corrugated fiberboard, the directionality of the strength (unevenness in the direction) of the corrugated fiberboard is reduced allowing the forks to be inserted to support the pallet


10


from any direction. Note that the pallet


10


with the load unit


114


loaded thereon may be intermediately packaged after being removed from the production line


310


. In this case, the load unit


114


comprising loaded stacks of photosensitive printing plates


112


may be formed after the lower intermediate packaging material


124


A has been spread on the loading tray


12


externally of the production line


310


.




Next, as is shown in

FIG. 5

, the periphery of the load unit


114


is externally wrapped with external packaging material


116


. In the present embodiment, the external packaging material


116


is formed from a pair of side surface external packaging materials


118


each comprising two sheets of corrugated fiberboard


18


adhered together and a top surface external packaging material


128


also comprising two sheets of corrugated fiberboard adhered together. The inner side corrugated fiberboard of the two sheets of corrugated fiberboard which form each side surface external packaging material is substantially the same height as the load unit


114


. The outer side corrugated fiberboard is higher than the inner side corrugated fiberboard by the height of the thickness of the top surface external packaging material


128


. Note that it is not absolutely necessary to form the side surface external packaging material and top surface external packaging material from two sheets of corrugated fiberboard adhered together, and three or more sheets may be adhered together or only one sheet may be used. Moreover, it is not absolutely necessary that the sheets be adhered together.




The pair of side surface external packaging materials


118


are placed in surface contact with the front surface


114


A and the rear surface


114


B of the load unit


114


(see

FIG. 3

for both) intermediately packaged with the intermediate packaging material


124


and the portions which extend beyond the sides of the load unit


114


in the widthwise direction thereof are bent and set in surface contact with the side surfaces


114


C of the load unit


114


(see FIG.


3


). At this time, because the loading tray


12


has been formed larger than the load unit


114


in accordance with the above formulas (1) and (2), the bottom edge of the side surface external packaging material


116


is positioned by being aligned with the portion of the top surface of the loading tray


12


which extends outwards past the load unit


114


allowing the external packaging task to be easily carried out.




As is shown in

FIG. 6

, the top surface of the load unit


114


is covered by a top surface external packaging material


128


. The top surface external packaging material


128


has a predetermined shape so as to fit exactly inside the outer sheet of corrugated fiberboard which forms the side surface external packaging material


118


. Accordingly, the top surface external packaging material


128


is disposed in contact with the top surface of the load unit


114


and the top side of the inner sheet of corrugated fiberboard forming the side surface external packaging material


118


. The side surface external packaging material


118


is then fixed to the loading tray


12


and to the top surface external packaging material


128


with adhesive tape


126


. Thus, the top surface external packaging material


128


and the side surface external packaging material


118


are joined together forming the external packaging material


116


.




Note that the relationship between the shape and height of the side surface external packaging material


118


and the shape and thickness of the top surface external packaging material


128


is not limited to the above. For example, the height of the corrugated fiberboard forming the side surface external packaging material


118


may be the same as the height of the intermediately wrapped load unit


114


and the thickness of the top surface external packaging material


128


added together (when the side surface external packaging material


118


is formed from a plurality of sheets of corrugated fiberboard, the height of all the sheets of corrugated fiberboard is set as the same), and the top surface external packaging material


128


is then placed on the top surface of the intermediately packaged load unit


114


on the inside of the side surface external packaging material


118


. Further, the height of the corrugated fiberboard forming the side surface external packaging material


118


may be set at the same height as the intermediately packaged load unit


114


(when the side surface external packaging material


118


is formed from a plurality of sheets of corrugated fiberboard, the height of all the sheets of corrugated fiberboard is set as the same), and the top surface external packaging material


128


placed on top of both the top side of the side surface external packaging material


118


and the top surface of the intermediately packaged load unit


114


. When the side surface external packaging material


118


and the top surface external packaging material


128


are formed by having a plurality of sheets of corrugated fiberboard placed side to side in layers, the height of the sheets of corrugated fiberboard forming the side surface external packaging material


118


can be increased continuously from the inner side to the outer side so that the top sides of the side surface external packaging material


118


have a stepped configuration. The top surface external packaging material


128


may also be formed to match the shape of the top sides of the side surface external packaging material by being formed in a stepped configuration, namely, where the size of the top surface external packaging material continually increases going from the bottom towards the top thereof. The top surface external packaging material


128


is then placed on the top surface of the load unit


114


in such a way that the side surface external packaging material


118


and the top surface external packaging material


128


contact each other such that the stepped portions of each fit together.




Note also that it is not necessary for the side surface external packaging material


118


to be formed in two separate sections, as described above and, provided that the external surface of the intermediately packaged load unit


114


is externally packaged, the shape and structure of the external packaging material is not particularly limited. For example, four sheets of side surface external packaging material may be formed so that they each cover a side of the external surface of the load unit


114


and then disposed at the external surfaces of the load unit


114


. Alternatively, the four sheets of side surface external packaging material may be formed in advance into a four sided cylinder which is then fitted around the load unit


114


from the top thereof. It is also possible to adjust the size of the side surface external packaging material


118


so that a predetermined gap is formed between the side surface external packaging material and the intermediately packaged load unit


114


, and to insert a new separate external packaging material (such as a cushioning material) into the gap after the side surface external packaging material has already been put in place.




Thereafter, the periphery of the external packaging


116


is packaged with a resin cover


122


. This protects the external packaging material


116


and the stacks


12


(the photosensitive printing plates) from moisture and dust in the air and from rain and the like. Note that if the stacks


112


(the photosensitive printing plates) are sure to be protected from moisture and dust in the atmosphere and from rain and the like by the intermediate packaging material


124


and the external packaging material


116


, then the cover


122


is not required.




Lastly, as is shown in

FIG. 7

, the load unit


114


which is packaged by the cover


122


and external packaging material


116


and the pallet


10


are fastened by resin or metal bands


120


(In

FIG. 7

, two lengthwise and two widthwise bands have been used, however, the number of bands is not limited to two and three or more may be used). This prevents the stacks of photosensitive printing plates


112


from shifting position or falling over on the pallet


10


and enables handling during transport or storage to be carried out with ease. Note that the cover


122


may be put in place after the external packaging material


116


and the pallet


10


have been fastened by the bands


120


.




In this way, because stacks of photosensitive printing plates


112


are loaded on a pallet


10


to form a load unit


114


and are fastened to the pallet


10


, if they are reloaded onto another transporting means while being transported (for example, if they are loaded from a truck onto another truck, railcar, ship, or the like), the entire pallet and load can be reloaded which leads to excellent operating efficiency. Moreover, because, in this state, the peripheral portions of the loading tray


12


extend beyond the load unit


114


and the external packaging material


116


to form the extending portion


20


, even if external elements strike against the pallet


10


during transportation, the external element is prevented from striking against the stacks


112


by the extending portion


20


, thus protecting the photosensitive printing plates. In particular, the photosensitive printing plates or heat sensitive printing plates loaded onto the pallet


10


of the present embodiment are all formed in the shape of a thin plate, therefore, if there is any deformation or scratching on the corners, sides or inner portions, then problems may occur such as the image being blurred when the plates are developed by heat or light sensitivity, or the ink not being spread uniformly during printing. Accordingly, the packaging material needs to have a rigidity and strength sufficient to prevent the printing plates from being deformed and the like during transportation. By transporting the printing plates loaded on the pallets


10


of the present embodiment, the above deformation and scratching can be prevented.




A plurality of pallets


10


on which are loaded load units


114


can be stacked vertically one on top of the other. In this case, the base plate


14


of the pallet


10


makes surface contact with the top surface external packaging material


128


directly beneath the pallet


10


and the leg portions


16


do not directly touch the top surface external packaging material


128


. Namely, because the weight of a pallet


10


and load unit


114


acts on the entire top surface of the load unit


114


underneath thus spreading the weight, the load unit


114


is protected. A plurality of pallets


10


loaded with load units


114


can also be lined up side by side, front to rear, and vertically, and thus be loaded onto a separate larger pallet.




When the photosensitive printing plates are loaded into an apparatus at their destination and used, the bands


120


are unfastened (if fitted, the cover


122


is also removed), and the external packaging


116


is opened. Because the loading tray


12


of the pallet


10


is formed slightly larger than the load unit


114


, the stacks


112


can be set directly in the device while still loaded on the pallet


10


. Naturally, the stacks


112


may also be removed from the pallet


10


and set in the apparatus. Note that, in order to set the stacks directly in the apparatus in this way, the loading tray


12


may also be made the same size as the load unit


114


or made smaller than the load unit


114


.




When all the stacks of photosensitive printing plates


112


loaded on the pallet


10


are loaded into the apparatus, only the pallet


10


remains. If the pallet


10


has retained a constant shape and strength, it may be reused, however, even if it is not capable of being reused, because the loading tray


12


, leg portions


16


, and base portion


14


which form the pallet


10


are all made from corrugated fiberboard, they can be recycled. Disposal of waste is also easy.




Note that it is not necessary for the lower intermediate packaging material


124


A to be large enough to extend out beyond the load unit


114


, and it may be substantially the same size as the load unit


114


. In this case, the upper intermediate packaging material


124


B is made large enough to reach the loading tray


12


and is fixed to the top surface (i.e. portion formed as the extending portion


20


) or peripheral surface of the loading tray


12


with adhesive tape forming intermediate packaging having a high level of moisture proofness. In addition, the lower intermediate packaging material


124


A may be omitted providing intermediate packaging having a general level of moisture proofness.





FIG. 8

shows a pallet


30


according to the second embodiment of the present invention. In this pallet


30


, only the structure of the loading member onto which is loaded a load unit


114


is different to the pallet


10


of the first embodiment. In the explanation below, the same structural elements and members as in the pallet


10


of the first embodiment are given the same symbols and an explanation thereof is omitted.




The loading tray


12


of the pallet


30


of the second embodiment has the same structure as the loading tray


12


of the first embodiment, however, it is further provided with a step portion


32


formed in the center portion of the loading tray


12


from a plurality of sheets of corrugated fiberboard loaded side to side on top of each other. The width W


2


and length L


2


of the step portion


32


are made the same as the width W and length L of the load unit


114


(see FIG.


3


). A loading member is formed from the load plate


12


and step


32


.




When stacks


112


are accumulated on the pallet


30


, a positioning guide


332


provided in the accumulating device


320


on the production line


310


(see

FIG. 13

) is placed in contact with the peripheral portions


32


A of the step


32


(shown by the double dot-dash line in FIG.


8


). The height of the positioning guide


332


is higher than the height of the step


32


, therefore, when a stack


112


is placed on the step


32


, the stack


112


is positioned by being guided by the positioning guide


332


. Note that it is also possible to provide positioning guides


332


at both ends of the pallet


30


in the longitudinal direction thereof.




Moreover, unlike the first embodiment, the stack


112


is placed directly on the step


32


without using the lower intermediate packaging material


124


A (see FIG.


3


). When a load unit


114


has been formed from a predetermined number of stacks


112


, the upper intermediate packaging material


124


B is placed on the top surface of the load unit


114


. The upper intermediate packaging material of the second embodiment


124


B is made to a predetermined size so that when the portions of the upper intermediate packaging material


124


B which extend out past the top surface of the load unit


114


are bent down so as to be in surface contact with the side surfaces of the load unit


114


(the front surface


114


A, the rear surface


114


B, and the side surfaces


114


C), these portions reach the peripheral portions


32


A of the step portion


32


.




The upper intermediate packaging material


124


B and the peripheral portions


32


A of the step portion


32


are fastened together with adhesive tape around the entire periphery of the load unit


114


. The step portion


32


is formed to a predetermined size so that the width W


2


and length L


2


thereof are the same as the width W and length L of the of the load unit


114


. Thus, because the external surfaces of the load unit


114


and the peripheral portions


32


A of the step portion


32


are flush with each other, the upper intermediate packaging material


124


B can be placed in surface contact with both and the intermediate packaging process is simplified. If the upper intermediate packaging material


124


B is given sufficient length the bottom edge thereof can even be placed in contact with the top surface of the loading tray


12


simplifying the intermediate packaging process still further. Because the load unit


114


is contained inside the upper intermediate packaging material


124


B in unbroken surface contact with the inner surface thereof, the load unit


114


is securely fixed to the pallet


30


. Note that the upper intermediate packaging material


124


B may also be fixed to the top surface or peripheral surfaces of the loading tray


12


with adhesive tape


126


.




The load unit


114


is thus placed in a state of high moisture proofness by being packaged with the intermediate packaging material


124


in this way and the pallet


30


and load unit


114


are then removed from the production line. Note that, in the same way as in the first embodiment, the pallet


30


with the load unit


114


loaded thereon may be intermediately packaged after being removed from the production line


310


. In this case, the load unit


114


is formed externally of the production line


310


after the lower intermediate packaging material


124


A has been spread on the loading tray


12


.




Also in the same way as in the first embodiment, the load unit


114


may be externally packaged using the external packaging material


116


. At this time, because the lower side of the side surface external packaging material


118


can be disposed in surface contact with the peripheral portions of the step portion


32


, the lower side of the side surface external packaging material


118


can be securely fixed to the step


32


and there is no inadvertent shifting in the position thereof. Further, in the same way as in the first embodiment, by using bands


120


and a cover


122


, the stacks


112


can not only be fixed more firmly to the pallet


30


, but the printing plates can be securely protected from moisture and dust in the atmosphere and rain and the like.




Moreover, because, in this state, the outer edge portion of the loading tray


12


forms an extending portion


20


which extends out past the load unit


114


and the external packaging material


116


, protection of the load unit


114


can be ensured.




Note that, in the second embodiment, in the same way as the first embodiment, the lower intermediate packaging material


124


A is placed on the step


32


. The portion thereof extending out past the load unit


114


is then bent up and the portion thereof which overlaps with the upper intermediate packaging material


124


B is fastened thereto with adhesive tape


126


providing complete moisture proof protection.





FIG. 10

shows a pallet


40


according to the third embodiment of the present invention. Only the structure of the loading member is different from the pallet


10


of the first embodiment. The same structural elements and members as in the pallet


10


of the first embodiment are given the same symbols and an explanation thereof is omitted.




In the pallet


40


of the third embodiment, a pair of fixed boards


42


are provided standing vertically upright from each edge in the transverse direction of the loading tray


12


. The loading member is formed from the loading tray


12


and the fixed boards


42


. The spacing D


1


between the fixed boards


42


is found by the following formula which takes into consideration the width W of the load unit


114


and the depth D of the intermediate packaging


124


and external packaging


116


.








D


1=


W


+2


D


  (3)






Accordingly, when a load unit


114


is loaded onto the loading tray


12


, the portion where the fixed boards


42


are provided (the vicinity of both transverse edges) and the fixed boards


42


form the extending portion


20


extending out past the load unit


114


.




When stacks of photosensitive printing plates


112


fed from the production line


310


(see

FIG. 13

) are loaded onto the pallet


40


, because the stacks fed onto the loading tray


12


are positioned by the fixed boards


42


, the task of accumulating the stacks is simplified.




After the stacks have been accumulated, then, in the same way as in the first embodiment, the load unit


114


is made completely moisture proof by being packaged with the intermediate packaging material


124


(the lower intermediate packaging material


124


A and the upper intermediate packaging material


124


B). Because the vicinity of both transverse edges of the loading tray


12


and the fixed boards


42


operate as the extending portion


20


extending out past the stacks


112


, the stacks are protected by the extending portion


20


.




When the stacks


112


are externally packaged using the external packaging


116


(see FIG.


4


), because the spacing D


1


between the fixed boards


42


is set in accordance with the above formula (3), the stacks can be externally packaged in such a way that the external packaging material


116


fits between the stacks


112


and the fixed boards


42


. The result of this is that the external packaging material


116


is held from the outside by the fixed boards


42


and does not shift in position. By further fastening the external packaging material


116


to the fixed boards


42


using adhesive tape


126


, the external packaging material


116


can be securely fixed to the pallet


40


. In the same way as in the first embodiment, using the bands


120


and the cover


122


enables the stacks


112


to be even more firmly fastened to the pallet


40


.




Note that it is also possible to provide fixed boards in the same way as the fixed boards


42


at both longitudinal ends of the loading tray


12


. In this case, the spacing D


2


between the fixed boards may be set in accordance with the formula below, which takes into consideration the length L of the load unit


114


and the depth D of the external packaging


116


.








D


2


=L


+2


D


  (4)






The intermediate packaging is not limited to the completely moisture proof packaging described above, and the lower intermediate packaging


124


A may be high moisture proof intermediate packaging being substantially the same size as the bottom surface of the load unit


114


, or general moisture proof intermediate packaging being smaller than the bottom surface of the load unit


114


.





FIG. 11

shows a pallet


50


according to the fourth embodiment of the present invention. In this pallet


50


only the structure of the loading member differs from the pallet


10


of the first embodiment and the same structural elements and members as in the pallet


10


of the first embodiment are given the same symbols below and a description thereof is omitted.




In the pallet


50


of the fourth embodiment, extending boards


54


and


56


extend outwards from both longitudinal edges and both transverse edges of the loading tray


52


. Bend lines


58


are formed in the border portions between the loading tray


52


and the extending boards


54


and


56


(the single dot-dash lines in

FIG. 11

) enabling the extending boards


54


and


56


to be bent upwards (and, accordingly, making the area inside the bend lines


58


act as the actual loading tray). The spacing D


3


of the extending board


54


when the extending boards


54


and


56


are bent 90 degrees upwards along the bend lines


58


is set in accordance with the following formula with the length of the load unit


114


taken as L, the width thereof taken as W, and the depth of the external packaging taken as D, in the same way as for the pallet


10


of the first embodiment.








D


3


=L


+2


D


  (5)






In the same way, the spacing D


4


of the extending board


56


is set in accordance with the following formula:








D


4


=W


+2


D


  (6)






Note that the structure of the bend lines


58


is not specifically limited providing that the extending boards


54


and


56


are able to be bent upwards. For example, notches may be cut from the bottom side of the loading tray


52


creating thin portions at which the extending boards can be easily bent.




When stacks


112


are loaded on the pallet


50


forming a load unit


114


to be intermediately packaged, the stacks


112


are first loaded onto the loading tray


52


to form a load unit


114


(see

FIG. 3

) before the extending boards


54


and


56


have been bent upwards. After the load unit


114


has been loaded on the loading tray


52


, the load unit


114


is intermediately packaged with intermediate packaging material


124


(i.e. lower intermediate packaging material


124


A and upper intermediate packaging material


124


B) in the same way as in the first embodiment. This intermediate packaging may be either complete moisture proofing, high level moisture proofing, or general moisture proofing.




After the load unit


114


has been externally packaged in a predetermined position by the external packaging material, the extending boards


54


and


56


are bent along the bend lines


58


, as shown by the double dot-dash lines in

FIG. 8

, so as to be in surface contact with the side surfaces


114


C (see

FIG. 3

) of the load unit


114


. Because the width of the thickness of the extending boards


54


and


56


thus becomes the extending portion extending out past the load unit


114


and external packaging material


116


, the load unit


114


is protected. Moreover, because the external packaging material


116


is externally held by the extending boards


54


and


56


, there is no shifting in the position of the external packaging material


116


. If the external packaging material


116


is further fastened to the extending boards


54


and


56


with adhesive tape


126


, the external packaging material


116


is securely fixed to the pallet


50


. As in the first embodiment, the use of bands


120


and a cover


122


enables the stacks


112


to be fixed more firmly to the pallet


50


.




Note that it is possible to provide only the extending boards


54


and not the extending boards


56


in the pallet


50


or, conversely, to provide only the extending boards


56


and not the extending boards


54


. The shape of the extending boards


54


and


56


is also not limited to that described above and the length of the extending boards


56


may be made the same as the length L of the load unit


114


. In addition, the length of the extending boards


54


may be made the same as the width W of the load unit


114


.




It is also possible to first bend the extending boards


54


and


56


upwards at 90 degrees or almost 90 degrees (i.e. on a slope) and then load the stacks


112


. In this case, because the stacks


112


are positioned by the extending boards


54


and


56


or by the bend lines


58


, the task of loading is simplified.





FIG. 12

shows a pallet


70


according to the fifth embodiment of the present invention. In the pallet


70


, only the structure of the loading member differs from that of the pallet


10


of the first embodiment and the same structural elements and members as in the pallet


10


of the first embodiment are given the same symbols and a description thereof is omitted.




The size of the loading tray


72


of the pallet


70


of the fifth embodiment is formed in accordance with the above described formulas (1) and (2), in the same way as the pallet


10


of the first embodiment.




A plurality of housing portions


74


having a uniform width are formed in both longitudinal ends of a loading tray


72


running longitudinally towards the center thereof (in the present embodiment, there are four in the front surface


72


A and four in the rear surface


72


B, making a total of eight). The housing portions


74


in the front surface


72


A of the loading tray


72


are open at the top and at the front surface


72


A. Similarly, the housing portions


74


in the rear surface


72


B of the loading tray


72


are open at the top and at the rear surface


72


B.




The position and shape of each of the housing portions


74


is determined so as to correspond to accumulating arms


334


provided in the accumulating apparatus


320


on the production line


310


(see FIG.


13


). Namely, as is shown in

FIG. 12

, an accumulating arm


334


having a plurality of forks


336


(two in

FIG. 12

) is provided in the accumulating apparatus


320


, and after the photosensitive printing plates are produced they are accumulated and positioned on the accumulating arm


334


. When a stack


112


is formed by accumulating a predetermined number of photosensitive printing plates, the accumulating arm


334


is moved so that the stack


112


is loaded on the loading tray


72


of the pallet


70


. At this time, because the housing portion


74


is open at the top thereof, and the forks


336


of the accumulating arm


334


are housed in the housing section


74


, the forks


336


do not become caught between the stack


112


and the loading tray


72


.




Moreover, because the housing portions


74


are open the at the front surface


72


A and rear surface


72


B of the loading tray


72


, after a stack


112


has been loaded onto the loading tray


72


, the forks


336


can be removed from the housing portions


74


.




In the same manner as for the pallet


10


of the first embodiment, a load unit


114


is formed on the loading tray


72


of the pallet


70


which can be intermediately packaged and externally packaged with the intermediate packaging material


124


and external packaging material


116


. However, the task of accumulating stacks


112


is made even easier in particular because, as explained above, the stacks


112


of photosensitive printing plates are loaded on the loading tray


72


while loaded on the forks


336


of the accumulating arm


334


, and the forks


336


can be removed from the housing portions


74


without the need for any further action. Note that not only the forks


336


of the accumulating arm


334


, but even the forks of a forklift can be prevented from being caught between the stacks


112


and the loading tray


72


and also removed from the housing portions


74


.




The peripheral edge portions of the loading tray


72


act as the extending portions


20


extending out beyond the load unit


114


(see

FIG. 4

) thereby protecting the photosensitive printing plates forming the stacks


112


. However, as with the pallet


10


of the first embodiment, it is not absolutely necessary to provide the extending portion


20


.




Note also that, in the examples given in the above descriptions, corrugated fiberboard was used to form all of the structural members forming a pallet (i.e., the loading trays


12


,


52


, and


72


, the base plate


14


, the leg portions


16


, the step portion


42


, and the fixed plate


42


), however, the paper used to form these structural members is not limited to corrugated fiberboard. Namely, provided that the paper can maintain a constant shape and the strength necessary as a pallet to support a load, and can be easily recycled or disposed of, then any paper can be used. For example, cardboard, Kraft paper, or a paper honeycomb structure material may all be used. Alternatively, appropriate combinations of these types of paper can be used, or else a different type of paper may be used for each structural member. In any case, the use of paper to form the structural members provides lighter weight pallets which are easier to handle during transport or storage compared to conventional metal or resin pallets. Moreover, by manufacturing the pallets from paper, they can be produced cheaply. Note that even if paper other than corrugated fiberboard is used to form the loading tray, by superposing a plurality of sheets of paper with the direction of the grain of at least one sheet intersecting the direction of the grains of the other sheets, the directionality of the strength of the paper (variations in the strength of the paper depending on the direction) can be reduced and the pallet can be supported no matter which direction the forks are inserted from.




When corrugated fiberboard is used for each structural element, it is preferable from the viewpoint of maintaining a uniform strength and the like, that the following conditions are met.




The most preferable type of flute of the corrugated fiberboard is a BA flute or AB flute, followed in order by an A flute, a B flute, and a C flute. The most preferable type of liner for the front and rear liner of the corrugated fiberboard is AA liner, followed by A liner, B liner, and C liner. The basic weight of the front and rear liners is from 160 (g/m


2


) to 340 (g/m


2


). The most preferable type of ruffled inner layer of the corrugated fiberboard is a strengthened ruffled inner layer, followed by an A ruffled inner layer, a B ruffled inner layer, and a C ruffled inner layer. The basic weight of the ruffled inner layer is from 115 (g/m


2


) to 280 (g/m


2


)./




If a honeycomb structure material is used instead of the corrugated fiberboard, it is preferable that the same front liner, rear liner, and center as for the above corrugated fiberboard are used.




If cardboard is used instead of the corrugated fiberboard, it is preferable that the basic weight thereof is from 600 (g/m


2


) to 2000 (g/m


2


).




Further, provided that each of the above structural elements are disposed so as not to separate accidentally or change position relative to each other, it is not absolutely necessary for them to be fastened together through the adhesion of an adhesive agent or adhesive tape. For example, the loading tray


12


and leg portion


16


can be fixed so as not to separate or shift position by forming an engaging portion or fitting portion in the loading tray


12


and leg portion


16


and engaging or fitting these portions together. The lower intermediate packaging material


124


A and the upper intermediate packaging material


124


B may be adhered together using an adhesive agent as may the external packaging material


116


and the loading tray


12


.




Naturally, the load loaded onto the pallet of the present invention is not limited to a load unit


114


formed from a stack


112


of photosensitive printing plates as described above and the load unit


114


may be formed from a stack


112


of a wide range of general printing plates, including heat sensitive printing plates and the like.




A specific example of a load unit containing printing plates (photosensitive printing plates and heat sensitive printing plates) is given below.




Firstly, an aluminum plate measuring 0.3 mm×1310 mm×1050 mm on which is coated a photosensitive or heat sensitive layer may be used as the printing plate.




Backing paper


330


made from bleached Kraft pulp having a basic weight Of 30˜45 g/m


2


, a density of 0.7˜0.85 g/cm


3


, a water content of 4˜6%, a Beck smoothness of 50˜200 seconds, and a pH of 4˜6 may be used as the backing paper


330


. This backing paper


330


is then closely adhered to the coating layer (photosensitive or heat sensitive) on the aluminum plate and between 10 and 100 printing plates and backing paper are alternately superposed. Protective cardboard manufactured from wastepaper and having a basic weight of 400˜1500 g/m


2


, a density of 0.7˜0.85 g/cm


3


, a water content of 4˜8%, a Beck smoothness of 3˜20 seconds, and a pH of 4˜6 is then disposed below and above the superposed materials forming a product stack


112


. When a stack


112


is formed of between 10˜100 printing plates, the facing sides of the protective cardboard and the printing plates may be held with Kraft adhesive tape in two places each so that they do not shift against each other.




The light proof, moisture proof paper (alumikraft paper) which can be used for the intermediate packaging material


124


may be one in which 6 μm aluminum foil is adhered to a Kraft paper obtained from 13 μm low density polyethylene and having a basic weight of 85 g/m


2


. The stacks


112


are intermediately packaged using this light proof, moisture proof paper and are then made fast using adhesive tape


126


. The light proof, moisture proof paper is not, however, limited to the above example and, for example, a light proof, moisture proof paper, provided by further adhering a 10-70 μm low density polyethylene layer to the aluminum foil whose structure was described above, may be used.




The stacks


112


are also not limited to those described above. For example, the stacks may have no backing paper, alternatively, the stacks may contain up to a maximum of 1500 superposed printing plates with the above described protective cardboard inserted between every 20˜100 plates, or the stacks


112


may also be formed from up to a maximum of 1500 printing plates with the protective cardboard only provided above and below the stack


112


.




It is also not necessary to form the external packaging material


116


from the above described corrugated fiberboard and, provided that they are capable of protecting the load unit


114


from external shocks, then, for example, cardboard, Kraft paper, and honeycomb structure paper materials may be used as external packaging for the load unit


114


. From the above viewpoint, by using a material having a high degree of rigidity such as paper hardboard or the like, as the outermost member of the external packaging


116


, so that even if the energy from a strong shock is applied to the external packaging material


116


, the external packaging material


116


is not deformed and the load unit


114


can be more effectively protected. In the same way, by using an elastic material, for example, such as foam resin, for the innermost member of the external packaging material (the member in contact with the intermediate packaging material


124


), the energy from a strong shock can be absorbed by the elastic deformation of this elastic material and the load unit


114


can be more effectively protected.



Claims
  • 1. A load packaging method for loading a load on a loading member of a pallet and intermediately packaging the load with intermediate packaging material, wherein the pallet comprises:a loading member made from paper onto which a load is loaded; a leg member made from paper which is fixed to the loading member and, as well as supporting the loading member when a load is loaded on the loading member, forms an insert body receiving member into which is inserted an insert body used during transportation; and a base member made from paper which is fixed to the opposite side of the leg member to the loading member, wherein the load packaging method comprises: a load loading step for loading the load onto the loading member; an intermediate packaging step for intermediately packaging the top surface and side surfaces of the load loaded onto the loading member with the intermediate packaging material, wherein said intermediate packaging step includes placing an upper intermediate packaging material substantially centrally on the top surface of the load and bending down a portion which extends out past the top surface of the load so as to be in surface contact with the side surfaces of the load; and a fastening step for fastening the intermediate packaging material with which the load was intermediately packaged in the intermediate packaging step to the loading member.
  • 2. A load packaging method for loading a load on a loading member of a pallet and intermediately packaging the load with intermediate packaging material, wherein the pallet comprises:a loading member made from paper onto which a load is loaded; a leg member made from paper which is fixed to the loading member and, as well as supporting the loading member when a load is loaded on the loading member, forms an insert body receiving member into which is inserted an insert body used during transportation; and a base member made from paper which is fixed to the opposite side of the leg member to the loading member, wherein the load packaging method comprises: a load loading step for loading the load onto the loading member; an intermediate packaging step for intermediately packaging the top surface and side surfaces of the load loaded onto the loading member with the intermediate packaging material; and a fastening step for fastening the intermediate packaging material with which the load was intermediately packaged in the intermediate packaging step to the loading member, wherein, before the step to load a load on the loading member, a laying step is performed to lay intermediate packaging material, which is substantially the same shape as the loading member, on the loading member.
  • 3. The load packaging method according to claim 2, wherein the loading member includes a step portion and wherein, in the step to load the load on the loading member, the side surfaces of the load and side portions of the step portion are made flush, and in the intermediate packaging step, the intermediate packaging material is placed in surface contact with both the side surfaces of the load and the side portions of the step portion.
  • 4. A load packaging method for loading a load on a loading member of a pallet and intermediately packaging the load with intermediate packaging material, wherein the pallet comprises:a loading member made from paper onto which a load is loaded; a leg member made from paper which is fixed to the loading member and, as well as supporting the loading member when a load is loaded on the loading member, forms an insert body receiving member into which is inserted an insert body used during transportation; and a base member made from paper which is fixed to the opposite side of the leg member to the loading member, wherein the load packaging method comprises: a load loading step for loading the load onto the loading member; an intermediate packaging step for intermediately packaging the top surface and side surfaces of the load loaded onto the loading member with the intermediate packaging material; and a fastening step for fastening the intermediate packaging material with which the load was intermediately packaged in the intermediate packaging step to the loading member, further comprising: a laying step for laying a lower intermediate packaging material formed to a larger size than the loading member on the loading member; a lower intermediate packaging step for loading a load onto the lower intermediate packaging material laid in the laying step and for bending upwards portions of the lower intermediate packaging material which extend out beyond the load thus intermediately packaging the bottom surface and a portion of or all of the side surfaces of the load; and a fastening step for intermediately packaging the top surface and side surfaces of the load loaded onto the loading member with an upper intermediate packaging material and fastening the upper intermediate packaging material to the lower intermediate packaging material.
  • 5. The load packaging method according to claim 4, wherein in the laying step, lower intermediate packaging material is laid while the extending portion is not bent, and in the lower intermediate packaging step, the lower intermediate packaging material and the extending portion are bent upwards.
  • 6. A load packaging method for loading a load on a loading member of a pallet and intermediately packaging the load with intermediate packaging material, wherein the pallet comprises:a loading member made from paper onto which a load is loaded; a leg member made from paper which is fixed to the loading member and, as well as supporting the loading member when a load is loaded on the loading member, forms an insert body receiving member into which is inserted an insert body used during transportation; and a base member made from paper which is fixed to the opposite side of the leg member to the loading member, wherein the load packaging method comprises: a load loading step for loading the load onto the loading member; an intermediate packaging step for intermediately packaging the top surface and side surfaces of the load loaded onto the loading member with the intermediate packaging material; and a fastening step for fastening the intermediate packaging material with which the load was intermediately packaged in the intermediate packaging step to the loading member, wherein the loading member includes a step portion and wherein, in the step to load the load on the loading member, the side surfaces of the load and side portions of the step portion are made flush, and in the intermediate packaging step, the intermediate packaging material is placed in surface contact with both the side surfaces of the load and the side portions of the step portion.
Priority Claims (1)
Number Date Country Kind
10-295139 Oct 1998 JP
Parent Case Info

This is a divisional of application Ser. No. 09/418,994 (Confirmation No. Unknown) filed Oct. 14, 1999, now U.S. Pat. No. 6,332,535, the disclosure of which is incorporated herein by reference.

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Number Name Date Kind
3618755 Kean et al. Nov 1971 A
3626860 Blatt Dec 1971 A
4027794 Olson Jun 1977 A
4044981 Richter Aug 1977 A
4171741 Fish Oct 1979 A
4445614 Mitsumori et al. May 1984 A
4966084 Motomaru Oct 1990 A
5503085 Rozek Apr 1996 A
5672412 Phares et al. Sep 1997 A
Foreign Referenced Citations (2)
Number Date Country
0 334 329 Sep 1989 EP
0 494 540 Jul 1992 EP