PALLET SKIRT

Abstract

A pallet skirt can be a unitary, foldable pallet skirt. The pallet skirt can comprise one or more strips of material joined to form a foldable rectangle-shaped or square-shaped form. The strip of material can have a width suitably determined to coincide with the height dimension of a pallet on the floor or shelf of a retail establishment. When unfolded to a rectangle or square, the rectangle or square can have the general size and shape of the “footprint” of the pallet(s) on which it will be used.

Description

TECHNICAL FIELD OF THE INVENTION

This application relates to pallet skirts, which are coverings designed to surround and enclose the perimeter of a pallet. The pallet skirt is designed to provide aesthetic appeal, product protection, and branding opportunities, as well as streamline the transport, handling, and display of palletized goods in various settings, such as retail environments or warehouses.

BACKGROUND OF THE INVENTION

A pallet is a flat, typically rectangular platform used to support and transport goods. It is commonly made from wood, plastic, or metal, and is designed with spaces or openings that allow forklifts or pallet jacks to lift and move it easily. Pallets are integral to modern logistics, enabling the efficient handling, storage, and shipping of products in bulk.

Pallets are used in warehouses, distribution centers and retail settings to consolidate multiple items into a single unit load, making it easier to transport large quantities of goods at once. Products are typically stacked on the pallet and secured with straps, shrink wrap, or other materials to keep them stable during handling and transport. Pallets can be loaded onto trucks, trains, ships, or planes for shipping, and they also simplify storage by allowing goods to be stacked in warehouses, maximizing vertical space.

In retail, pallets are sometimes used as display units, especially in big-box stores. When pallets are used this way, products can be sold directly from the pallet without unpacking, simplifying both stocking and sales operations. Pallets also aid in inventory management, as they are often tagged or labeled for easy tracking and identification of goods. Overall, pallets are a critical component in streamlining the supply chain, reducing manual labor, and optimizing the movement of goods from manufacturers to consumers.

Pallet skirts come in various types, each designed to meet different needs depending on the environment and application. One common type is the full-height pallet skirt, which covers not just the pallet base but also the goods stacked on it. These skirts are often used in retail environments where visual appeal, product protection, and branding are essential. They are typically made from durable materials like corrugated plastic or cardboard and can be printed with logos or product information to enhance the display and protect the items from dust or debris. Another type is the base-only pallet skirt, which wraps around the perimeter of the pallet but leaves the stacked goods exposed.

A pallet skirt is suitably made of cardboard, plastic, or fabric and is designed to protect the products stacked on the pallet from dust, dirt, and damage. Pallet skirts can also be used for branding or labeling purposes, allowing companies to print logos, product information, or barcodes on them.

In addition to protection, pallet skirts help improve the appearance of a palletized load by concealing the wooden pallet and providing a neat, uniform look. They are commonly used in retail environments where pallets are displayed on the sales floor

BRIEF SUMMARY

The present invention provides a foldable pallet skirt that can be easily transformed between a folded, compact state for shipping or storage and an unfolded state that surrounds a pallet in a rectangular or square configuration. The pallet skirt is designed to conform to the general size and footprint of standard pallets and is constructed from materials that allow for flexibility, durability, and customization.

The pallet skirt comprises one or more strips of material that are joined at their end portions to form a continuous, unitary loop or band. The material has two faces, separated by a plurality of fluted members that provide structural strength while allowing the material to be lightweight. Portions of one or both faces of the material are removed or scored to create a series of substantially parallel grooves or discontinuities that extend across the width of the strip. These grooves facilitate folding the material along predefined lines, allowing the pallet skirt to bend easily at the corners and transition between a folded state and an unfolded, rectangular state.

In its unfolded state, the pallet skirt forms a rectangular or square structure that wraps around the pallet, with the grooves positioned at the corners of the structure to aid in shaping the material. The width of the strip is chosen to match the height of the goods on the pallet or the dimensions of the pallet itself, depending on the application.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments will become better understood with regard to the following description, appended claims and accompanying drawings wherein:

FIG. 1 an example embodiment of a palletized load;

FIG. 2 is an example embodiment of a palletized load with a partially opened pallet skirt;

FIG. 3 is an example embodiment of a palletized load with a fully opened pallet skirt;

FIG. 4 is an example embodiment of a pallet skirt in a partially collapsed form;

FIG. 5 is a perspective, cutaway view of an example embodiment of a pallet skirt wall formed by corrugated material;

FIG. 6 is a perspective, cutaway view of an example embodiment of a pallet skirt wall showing a hinge portion;

FIG. 7 is a perspective view of an example embodiment of a foldable joint in a pallet skirt;

FIG. 8 is a perspective view of an example embodiment of a foldable joint in a pallet skirt:

FIG. 9 is perspective, blown up view of an example embodiment of a foldable joint 106, a pallet skirt interior portion and hinge portion;

FIG. 10 is a perspective, blown up view of an example embodiment of a pallet skirt foldable joint of hinge portion;

FIG. 11 is a perspective view of an example embodiment of a partially expanded pallet skirt;

FIG. 12 is a perspective view of an example embodiment of a pallet skirt in a fully extended form;

FIG. 13 is a perspective view of an example embodiment of a collapsible pallet skirt assortment bundle;

FIG. 14 is a perspective view of an example embodiment of a pallet skirt assortment bundle in fully encased, shipment form;

FIG. 15 is a perspective view of an example embodiment of a fully extended pallet skirt;

FIG. 16 is a perspective view of an example embodiment of a fully extended pallet skirt;

FIG. 17 is an example embodiment of a first side view of a fully extended pallet skirt;

FIG. 18 is an example embodiment of a second side view of a fully extended pallet skirt;

FIG. 19 is an example embodiment of a third side view of a fully extended pallet skirt;

FIG. 20 is top view of an example embodiment of a fully extended pallet skirt;

FIG. 21 is a bottom view of an example embodiment of a fully extended pallet skirt; and

FIG. 22 is a perspective view of an example embodiment of a partially collapsed pallet skirt.

DETAILED DESCRIPTION OF THE INVENTION

The systems and methods disclosed herein are described in detail by way of examples and with reference to the figures. It will be appreciated that modifications to disclosed and described examples, arrangements, configurations, components, elements, apparatuses, devices methods, systems, etc. can suitably be made and may be desired for a specific application. In this disclosure, any identification of specific techniques, arrangements, etc. are either related to a specific example presented or are merely a general description of such a technique, arrangement, etc. Identifications of specific details or examples are not intended to be, and should not be, construed as mandatory or limiting unless specifically designated as such.

In example embodiments, a pallet skirt is constructed from a strip of corrugated material, such as corrugated plastic, that has fluted members running between a first face and a second face. The strip is cut to a length that is sufficient to wrap around the perimeter of a pallet when formed into a rectangular shape. The strip is suitably joined at its two end portions by an overlapping bond, such as adhesive, thermal welding, or mechanical fastening, to create a continuous band or loop.

A particular example embodiment employs a corrugated plastic such as COROPLAST, sold by Coroplast, LLC, which is lightweight, durable, and resistant to environmental factors like moisture, dust, and impacts. Flutes of the corrugated material are oriented horizontally on all sections of the pallet skirt. This horizontal flute direction is critical for providing strength across the length of the pallet skirt, ensuring it maintains rigidity and durability while still allowing the necessary flexibility at the fold lines. The horizontal flute orientation also contributes to the skirt's overall stability when deployed around a pallet.

The strip includes a first face and a second face, with the fluted members sandwiched between these faces. In the context of corrugated plastic, flutes refer to the hollow, ribbed structures that run between two flat surfaces or walls of the material. These flutes are the internal corrugations or channels that give the material its rigid yet lightweight properties. The flutes create air pockets that provide structural strength, making the material durable and resistant to bending or crushing while keeping it lightweight. Portions of one or both faces are removed, creating a series of grooves that extend across the width of the strip. These grooves are substantially parallel to each other and spaced at intervals corresponding to the intended corners of the rectangular shape. The grooves allow the strip to fold easily at the corners of the pallet when the skirt is in use, providing a neat and rigid enclosure around the pallet.

The pallet skirt is suitably sold as a fully assembled, complete unit, eliminating the need for any assembly by the end user. This design ensures ease of use, as the skirt can be deployed immediately upon receipt without requiring additional steps such as fastening or bonding parts together. The user simply unfolds the pallet skirt, which has been pre-configured to fit standard pallet dimensions, and places it around the pallet.

Example embodiments employ cut-score technology to enhance the production of the pallet skirt. This technology involves precisely cutting or scoring the material at specific locations, creating fold lines or grooves without fully severing the material. Cut-score technology refers to a precise cutting or scoring method used on materials, typically for the purpose of creating fold lines or weakened sections without fully severing the material. In this process, shallow cuts or scores are made on the surface of a material, allowing it to bend or fold easily along the cut lines while retaining overall structural integrity.

Use of cut-score technique enables controlled deformation, making it easier to fold or shape materials like corrugated plastic, cardboard, or other sheet materials. By strategically scoring the material creates clean, predefined fold points, which are advantageous for products that need to transition between flat, compact forms and fully extended pallet skirt shapes pallet. Cut-score technology also enhances production efficiency by ensuring uniformity in the folding process and reducing the risk of cracking or tearing. These cut scores allow the pallet skirt to be easily folded along predefined lines, making it compact for storage and transport while maintaining its structural integrity when unfolded. The precise scoring ensures clean, sharp folds that align with the corners of the pallet, enabling the pallet skirt to quickly take its intended shape.

When not in use, the pallet skirt can be folded along these grooves into a compact form for efficient shipping and storage. In this folded state, portions of the interiorly facing surface of the strip come into contact with other portions of the interiorly facing surface, allowing the skirt to collapse into a flat, stacked configuration. This folding mechanism simplifies handling and reduces storage space requirements.

In the unfolded state, the pallet skirt assumes a rectangular configuration with four sides and four corners. The grooves or discontinuities are positioned at each of the four corners, allowing the material to bend and form right angles at these locations. The rectangular or square shape of the skirt matches the general footprint of standard pallets, ensuring a snug and secure fit around the pallet and its contents. The width of the strip is selected to align with the height of the palletized goods or the pallet itself, providing full coverage of the pallet sides.

The pallet skirt's foldable design allows for “drop and shop” convenience, meaning the user can easily unfold the skirt and place it around a pallet in a single motion, minimizing setup time. This makes it particularly suitable for retail environments where speed and efficiency are essential for stocking and displaying goods. Once unfolded, the pallet skirt maintains its shape around the pallet, providing a clean, professional appearance while protecting the palletized goods.

In example embodiments, the pallet skirt is constructed from materials that are both durable and lightweight, such as corrugated plastic. Corrugated plastic is particularly suitable due to its strength, resistance to damage, and ability to support high-quality printing. The material may also undergo surface treatments, such as corona discharge treatment, to enhance its adhesion properties for printing or bonding applications. The exterior surface of the pallet skirt can be printed with logos, product information, or barcodes, making it ideal for use in branding and product management.

The pallet skirt can be manufactured using various processes. A strip of corrugated plastic material is first cut to the desired length and width. Grooves are created by cutting or scoring portions of one or both faces of the material. The strip is then joined at its end portions to form a loop, and the grooves are aligned with the intended corners of the rectangular shape. The skirt can then be folded along the grooves for compact storage.

In some embodiments, multiple strips of material may be used to form the pallet skirt. In these cases, each strip may be joined to an adjacent strip using overlapping bonds, creating a continuous, unitary structure that can be folded and unfolded in the same manner as the single-strip embodiment.

The pallet skirt is highly versatile and can be used in a variety of settings, including retail displays, warehousing, and transportation. Its foldable design and ease of use make it a convenient solution for protecting and presenting palletized goods. Additionally, the customizable nature of the material allows for the creation of pallet skirts in different sizes, colors, and printed designs, further enhancing their utility in commercial applications.

The method for making the pallet skirt begins with providing a strip of corrugated plastic material. The strip has two end portions that define its length and two edges that define its width. The strip is formed with a first face and a second face, separated by fluted members. Portions of one or both faces are then removed or scored to form a plurality of substantially parallel grooves extending across the width of the strip. These grooves are spaced at intervals corresponding to the intended corners of the rectangular shape when the skirt is unfolded.

Next, the end portions of the strip are joined together using an overlapping bond. This bond may be created using adhesive, thermal welding, or another suitable method, depending on the material and the intended application. The completed pallet skirt can then be folded along the grooves for compact storage.

In some embodiments, multiple strips of material may be used to create the pallet skirt. In this case, the process involves providing a second strip of material and repeating the scoring and bonding steps for the second strip. The two strips are then joined at their respective end portions to form a continuous loop.

Once assembled, the pallet skirt can be placed in a folded state into a container for shipping or storage. In certain embodiments, multiple folded pallet skirts may be stacked and stored in a single container to optimize space.

FIG. 1 illustrates a palletized load 100 that includes pallet 20 and load 22 that is configured to receive collapsed, continuous loop base pallet skirt 102 around pallet 20. FIG. 2 illustrates palletized load 100 with a partially opened pallet skirt 102. FIG. 3 illustrates palletized load 100 with a fully opened pallet skirt 102 having a width W, fully extended and installed to circumvent pallet 20.

FIG. 4 illustrates a perspective view of pallet skirt 102 in a partially collapsed form. Included are first and second mirrored distal ends, illustrated by distal end 9. The distal ends include mirrored, opposing exterior walls illustrated by wall 104 and mirrored interior walls 130. The exterior walls and interior walls intersect at foldable joint 106. The interior walls intersect at foldable joints, illustrated by joint 108 disposed in mirrored interior portions, illustrated by interior portion 10.

FIG. 5 illustrates a perspective, cutaway view of wall 104, formed by corrugated material 120, such as corrugated plastic. Included are first and second opposed walls 122 and 124 separated and connected by flutes 126 forming a wall thickness T.

FIG. 6 illustrates a perspective, cutaway view of wall 104 showing hinge portion 128 suitably forming hinge joints 106 and 108. Hinge portion 128 is suitably formed by removal of wall material on one side, or by scoring along the hinge line. Wall movement in direction 127 is facilitated by hinge portion 128 suitably formed by foldable joints 106 and 108.

FIG. 7 illustrates a perspective view of a representative foldable joint formed by hinge portion 128 in corrugated material 120. FIG. 8 illustrates a perspective view of representative foldable joint 106 formed by hinge portion 128 facilitating wall movement in direction 132.

FIG. 9 illustrates a perspective, blown up view, of foldable joint 106, interior portion 110 and hinge portion 128 when the pallet skirt is in a semi-collapsed form. FIG. 10 illustrates a perspective, blown up view of foldable joint 108 of hinge portion 128.

FIG. 11 illustrates a perspective view of partially expanded pallet skirt 102, including relative positions of wall 104, foldable joint 106, foldable joints 108, interior walls 130 and pallet skirt exterior 140 and pallet skirt interior wall 142.

FIG. 12 illustrates a perspective view of pallet skirt 102 in a fully extended form, forming a rectangle with dimensions SW1 and SW2.

FIG. 13 illustrates a perspective view of a collapsible pallet skirt assortment bundle 200 having pallet skirts of different sizes, such as full pallet skirts 102A disposed in container portion 216A, half pallet skirts 102B disposed in container portion 216B and quarter pallet skirts 102C disposed in container portion 216C. Having different pallet skirt sizes makes distribution more efficient. Smaller pallet configurations are often used for partial shipments or smaller retail outlets, and the ability to use a half or quarter skirt simplifies the process without sacrificing quality or presentation. This versatility in pallet skirt options optimizes shipping practices, making it easier to handle and transport goods of varying sizes.

In terms of storage and shipping, having multiple pallet skirt sizes also optimizes space. Smaller skirts can be collapsed and bundled with larger skirts, providing the appropriate size for any shipment. This ensures that businesses don't need to store excessive amounts of oversized skirts when smaller ones are more suitable for the job.

Additionally, pallet load heights vary, and having different skirt sizes ensures that products of all heights are properly covered and protected. For taller or bulkier loads, full pallet skirts may be required, but shorter loads benefit from half or quarter skirts. This range of sizes allows companies to tailor their packaging to the specific needs of the products, ensuring a good fit every time. By offering full, half, and quarter pallet skirts, companies can meet a variety of logistical, retail, and branding needs with greater efficiency and precision. The availability of different sizes helps to reduce waste, improve presentation, and streamline both storage and transportation processes.

Pallet skirt bundle 200 is suitably formed by packaging walls, such as walls 210, 212 and 214. FIG. 14 illustrates a perspective view of pallet skirt assortment bundle 200 in fully encased, shipment form, sealed by seamed cover 220. Bundle 200 provides a Hand-Bundled Collapsible (HBC), referring to an associated process of manually folding and bundling the pallet skirts into a compact, collapsed state for easy storage and transport. The collapsible nature of the pallet skirts allows them to be bundled tightly to minimize space during shipping. Thus, the pallet skirts are prepared by hand in a way that optimizes the use of shipping containers or pallets, making the skirts ready for easy deployment once they arrive at their destination. The hand-bundling process ensures that the pallet skirts remain neatly folded and organized, allowing for quick handling and setup when needed.

FIG. 15 illustrates a perspective view of a fully extended pallet skirt. FIGS. 16, 17, 18 and 19 illustrate side views of all walls of a fully extend pallet skirt. FIGS. 20 and 21 illustrate top and bottom views of the fully extended pallet skirt. FIG. 22 illustrates a perspective view of a partially collapsed pallet skirt. FIG. 23 illustrates a perspective view of a nearly fully collapsed pallet skirt.

While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the spirit and scope of the inventions.

Claims

1. A pallet skirt, comprising: a strip of material, the strip of material having two end portions defining a length, the strip of material having a first face separated from a second face by a plurality of fluted members,portions of one of the first face or the second face being discontinuous to define a plurality of substantially parallel grooved discontinuities extending across a width of the strip of material,the strip of material joined at the two end portions to form a unitary strip in a rectangle shape having four sides and four corners, an exteriorly facing surface and an interiorly facing surface, and wherein four of the substantially parallel grooved discontinuities are juxtaposed with the four corners of the rectangle shape, andthe plurality of substantially parallel grooved discontinuities being disposed on the interiorly facing surface.

2. The pallet skirt of claim 1, further comprising one of the plurality of substantially parallel grooved discontinuities juxtaposed on one of the four sides.

3. The pallet skirt of claim 1, further comprising one of the plurality of substantially parallel grooved discontinuities juxtaposed on one of the four sides and one of the plurality of substantially parallel grooved discontinuities juxtaposed on an opposing of the four sides.

4. The pallet skirt of claim 1, wherein the unitary strip comprises six grooved portions.

5. The pallet skirt of claim 1, wherein the unitary strip comprises six grooved portions, wherein the six grooved portions are defined by discontinuities on the second face.

6. The pallet skirt of claim 1, wherein the unitary strip comprises plastic.

7. The pallet skirt of claim 1, wherein the unitary strip comprises corrugated plastic.

8. A pallet skirt, comprising: a strip of material, the strip of material having two end portions defining a length, the strip of material having a first face separated from a second face by a plurality of fluted members,portions of each of the first face and the second face being discontinuous to define a plurality of substantially parallel grooved discontinuities extending across a width of the strip of material, andthe strip of material joined at the two end portions to form a unitary strip having an exteriorly facing surface and an interiorly facing surface, and being deformable between a first folded state and a second rectangular state, the second rectangular state being a rectangle shaped strip having four sides and four corners, and wherein four of the substantially parallel grooved discontinuities are juxtaposed with the four corners of the second rectangular state.

9. The pallet skirt of claim 8, wherein the substantially parallel grooved discontinuities are disposed on the interiorly facing surface.

10. The pallet skirt of claim 8, wherein the first folded state comprises portions of the interiorly facing surface being in contacting relationship with other portions of the interiorly facing surface.

11. The pallet skirt of claim 8, wherein in the second rectangular state the unitary strip has two parallel sides having a first side width and two parallel sides having a second side width, wherein the first side width and the second side width are predetermined to approximate a size of a rectangular pallet.

12. The pallet skirt of claim 8, wherein the two end portions are joined in an overlapping bond.

13. The pallet skirt of claim 8, wherein the unitary strip comprises corrugated plastic.

14. A method for making a pallet skirt, comprising: providing a first strip of corrugated plastic material, the first strip of corrugated plastic material of having two first strip end portions defining a first strip length and two edges defining a first strip width, the first strip of corrugated plastic material having a first strip face separated from a second strip face by a first plurality of fluted members,removing a plurality of portions of the second strip face to form a plurality of substantially parallel first strip grooved discontinuities extending across the first strip width of the first strip of corrugated plastic material, andjoining the two first strip end portions in an overlapping bond.

15. The method for making a pallet skirt of claim 14, wherein the first strip of corrugated plastic material comprises printable plastic.

16. The method for making a pallet skirt of claim 14, wherein the first strip of corrugated plastic material comprises corona discharge treated corrugated plastic.

17. The method for making a pallet skirt of claim 14, further wherein: providing a second strip of corrugated plastic material, the second strip of corrugated plastic material having two second strip end portions defining a second strip length and two edges defining a second strip width, the second strip of corrugated plastic material having a third strip face separated from a fourth strip face by a second plurality of fluted members,removing a second plurality of portions of the third strip face to form a plurality of substantially parallel second strip grooved discontinuities extending across the second strip width of the second strip of corrugated plastic material, andjoining each of the two first strip end portions to one of the two second strip end portions to form a unitary strip having an exteriorly facing surface and an interiorly facing surface, and being deformable between a first folded state and a second unfolded state, the second unfolded state being a rectangle shaped strip having four sides and four corners.

18. The method of making a pallet skirt of claim 17, wherein joining comprises overlapping bonding.

19. The method for making a pallet skirt of claim 17, further comprising placing the pallet skirt in the first folded state into a container.

20. The method for making a pallet skirt of claim 17, further comprising placing a plurality of pallet skirts in the first folded state into a container.