US3648959A - Paperboard panel substitute for lumber - Google Patents

Paperboard panel substitute for lumber Download PDF

Info

Publication number
US3648959A
US3648959A US27840A US3648959DA US3648959A US 3648959 A US3648959 A US 3648959A US 27840 A US27840 A US 27840A US 3648959D A US3648959D A US 3648959DA US 3648959 A US3648959 A US 3648959A
Authority
US
United States
Prior art keywords
core
paperboard
skid
panel
corrugated
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US27840A
Inventor
Gary L Wagner
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Gaylord Container Corp
Fort James Corp
Original Assignee
Crown Zellerbach Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Crown Zellerbach Corp filed Critical Crown Zellerbach Corp
Application granted granted Critical
Publication of US3648959A publication Critical patent/US3648959A/en
Assigned to GAYLORD CONTAINER LIMITED, ONE BUSH STREET, SAN FRANCISCO, CA., 94104, A CAYMAN ISLANDS CO. reassignment GAYLORD CONTAINER LIMITED, ONE BUSH STREET, SAN FRANCISCO, CA., 94104, A CAYMAN ISLANDS CO. ASSIGNMENT OF ASSIGNORS INTEREST. SUBJECT TO CONDITIONS RECITED (SEE RECORD FOR DETAILS) Assignors: CROWN ZELLERBACH CORPORATION, A CORP OF NV.
Assigned to BANKERS TRUST COMPANY, A NY BANKING CORP. reassignment BANKERS TRUST COMPANY, A NY BANKING CORP. SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GAYLORD CONTAINER CORPORATION, A CORP. OF DE
Assigned to GAYLORD CONTAINER CORPORATION reassignment GAYLORD CONTAINER CORPORATION CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). EFFECTIVE DATE: DECEMBER 4, 1986 Assignors: GC ACQUISITION CORPORATION
Assigned to GAYLORD CONTAINER CORPORATION reassignment GAYLORD CONTAINER CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: GAYLORD CONTAINER LIMITED
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Images

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D19/00Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D19/0002Platforms, i.e. load supporting devices without provision for handling by a forklift

Definitions

  • a paperboard panel substitute for lumber particularly adapted for use as a skid for supporting an object, comprises a plurality of layers of corrugated paperboard forming an inner core, and an outer jacket of solidfiber paperboard enveloping the core and secured thereto.
  • the solid fiber jacket is formed by folding a sheet thereof about the core and adhesively bonding the same thereto.
  • the panel is pre-formed with an apertured portion to receive a fastening member adapted to be secured to an object to be supported.
  • Such apertured portion includes a knockout section which is displaced by a head on the fastening member to form a countersunk recess and a washer therefor.
  • Double wall corrugated paperboard which consists of two layers of corrugated medium, having outer liners and an intermediate liner, is desirably employed.
  • a plurality of congruent layers of such double wall corrugated paperboard may be placed one above the other to provide the core but it is advantageous and desirable to form the core by severing a sheet of double wall corrugated board medially thereof except through one of the outer liners, and to fold the same about the unsevered liner to provide at least four layers of corrugated medium secured to liners.
  • the entire core is enveloped by a strong jacket formed of relatively heavy solid fiber paperboard which is relatively rigid.
  • a pair of spaced apart double fold lines is provided on the solid fiberboard sheet, which when the sheet is folded about the core form edge walls engaging side edges of the core and which are of substantially the thickness of the core, and also a full panel secured to one side face of the core, and partial panels secured to the opposite side face of the core with their adjacent edges in substantial abutment.
  • the flutes and ridges of the corrugations of the core are desirably arranged to extend transversely of the length of the panel.
  • the panel thus formed is a substitute for lumber. It can be used to replace plywood and other forms of lumber parcels, and is particularly adapted to provide a support skid for objects. It can be sawed, and nailed to surfaces as with lumber, and screws can be readily fastened thereto. Moreover, it has the advantages over lumber is not splintering, shrinking or warping, and being without knots that can break out. Also it can be made much lighter than wood of comparable strength, and is more resilient than lumber. Hence, it will absorb shocks more readily; the latter being of particular advantage for use as a skid for supporting household appliances because it will not splinter into pieces that might scratch enameled surfaces ofsuch appliances.
  • the panel is preformed with at least one apertured portion to receive a fastening member for attachment to the appliance.
  • the apertured portion includes an enlarged opening in a corrugated layer adjacent the solid fiber outer sheet, which communicates with smaller openings through the panel to thus form a shoulder.
  • a knockout section substantially the size and shape of the enlarged opening, is formed in the solid fiber sheet over the enlarged opening.
  • the invention has as its objects among others, the provision of an improved lumber substitute panel particularly adapted for use as a skid for supporting a household appliance in a shipping container, which is economical to manufacture, strong and rigid, is provided with improved means for securing the panel, and which at the same time has the advantages of wood in being able to be sawed and receive fastening members, and yet none of the disadvantages of warping, splintering, and knots that can be displaced.
  • FIG. 1 is a plan view of a sheet of double wall corrugated paperboard for forming the core of a panel particularly adapted for use as a supporting skid; the view being broken away to shorten the same;
  • FIG. 2 is a similar plan view but illustrating the sheet of FIG. 1 folded into two congruent layers;
  • FIG. 3 is a plan view of the outer solid fiber jacket before it is folded about and secured to the core;
  • FIG. 4 is a transverse sectional exploded view of the core, and the jacket in a position to be folded about the core; the plane of the section being indicated by lines 5-5 in FIGS. 2 and 3;
  • FIG. 5 is a transverse sectional view of the assembled completed panel; the plane of the section being also indicated by the lines 5-5 in FIGS. 2 and 3;
  • FIG. 6 is an enlarged fragmentary plan view of the outer solid fiberboard jacket, illustrating a knockout section formed therein;
  • FIG. 7 is an isometric view of a pair of panels secured to a household appliance (shown in phantom lines) to provide skid supports therefor;
  • FIG. 8 is an enlarged transverse fragmentary section taken in a plane indicated by line 88 in FIG. 7, and illustrating a fastening member before it is cinched onto the appliance;
  • FIG. 9 is a section similar to FIG. 8 but illustrating the fastening member cinched, and the knockout section in the solid fiberboard jacket displaced therefrom;
  • FIG. 10 is an enlarged transverse sectional view taken in a plane indicated by line 10-10 in FIG. 7;
  • FIG. 11 is an enlarged fragmentary longitudinal section taken in a plane indicated by line 11-11 in FIG. 7, and illustrating adhesive applied to the raw ends of the panel to moisture proof the same by preventing wicking of water therethrough;
  • FIG. 12 is a plan view of an unapertured panel which may be employed as a wall panel, or as a substitute for plywood;
  • FIG. 13 is a fragmentary transverse section taken in a plane indicated by line 13-13 in FIG. 12.
  • FIGS. 1 through 11 The panel hereof which has been advantageously employed as a substitute for a flat oblong lumber skid in supporting a household appliance during shipment in a container, is illustrated in FIGS. 1 through 11, and comprises a core 2 of a plurality of layers of corrugated paperboard.
  • a jacket 3 of heavy solid fiber paperboard completely envelopes the core, being secured thereto by a suitable adhesive.
  • Such jacket comprises a full panel 4, as can be seen best from FIG. 10, adhesively secured to one side face of the core, a pair of partial panels 6, each substantially half the width of the full panel, adhesively bonded to the opposite side face of the core with their adjacent edges substantially in abutment at 7, and edge walls 8 engaging the lateral edges of core 2.
  • the sheet for jacket 3 is of solid fiber paperboard which as is well known in the industry, is formed by laminating two or more sheets of solid non-corrugated paperboard together to provide a solid fiber board of desired thickness (caliper) and weight.
  • a suitable caliper and weight for the purpose hereof is between about 60 to point (0.060 to 0.100 in.) which will vary in weight from about 220 to 375 lbs. per thousand sq. ft.
  • Solid fiber board of this character is very rigid and relatively nonfiexible, and the edge walls 8 of the panel will, therefore, form strong beams resistant to bending forces.
  • the core is formed of at least four layers of cor rugated medium overlying each other respectively, and of congruent shape substantially the same congruent shape and size as full panel 4 of the jacket between the inner fold lines 9.
  • Conventional so-called double wall corrugated paperboard is desirable, which in unfolded condition comprises two layers of conventional paperboard corrugated medium 11 each adhesively bonded to an outer facing liner sheet 12 and to an intermediate liner 12 as can be seen best from the enlarged views ofFIGS. l and 11.
  • These layers of corrugated paperboard may be provided by separate pieces of corrugated paperboard but it is advantageous to employ a unitary sheet, as shown in FIG. l, which is folded along a longitudinally extending center line to provide a core of oblong (rectangular) shape shown in FIG. 2.
  • the double wall corrugated sheet is severed by slitting along center line 13 (FIG. ll) all the way through except through one outer liner l2, and is then completely folded as shown in FIG. 2 and in enlarged FIG. 10, along such unsevered portion of the outer liner, which thus provides a hinge connection, with the adjacent faces of the folded double wall corrugated board in engagement.
  • the double wall corrugated paperboard may be of any conventional weight commonly employed known in the industry.
  • a suitable weight for the corrugated medium hereof is about 26 to 33 lbs. per thousand sq. ft. with liners varying in weight from about 30 to 50 lbs. per thousand sq. ft., although this is not critical as liners as high as 90 lbs. per thousand sq. ft have been employed.
  • a suitable weight for skid use is about 26 lbs. per thousand sq. ft. for the corrugated medium, and about 42 lbs. per thousand sq. ft. for the liners, which provides a Mullen test of about 350 lbs.
  • corrugated paperboard core 2 is so severed and folded that the corrugations and the flutes thereof run transversely with respect to the axial length of the panel.
  • the sheet for inner core 2 is folded along fold line 13 to bring the adjacent faces of the double wall corrugated board into engagement; and then with adhesive (indicated at 15 in FIG. 11) applied to the inside face of the sheet for jacket 3, it is folded with full panel 4 positioned over one face of the core and folded along the fold lines 9 to engage edge walls 8 with the side edges of the core and partial panels 6 with the opposite face of the core.
  • the panel is then passed through conventional compression rollers in a conventional manner to apply pressure and thus effect firm adhesive bonding of the jacket to the core.
  • thermoplastic or thermosetting resins such as thermoplastic or thermosetting resins
  • hot melt adhesives such as molten wax or plastic material
  • the skid is formed with apertured portions 22 to receive fastening members, as is shown in FIGS. 8 and 9.
  • apertured portions 22 are formed by providing sets of apertures in both the core and the jacket of the panel before they are assembled together.
  • small apertures 23 are formed in the parent core sheet adjacent one side of fold line l3. They register with large apertures 24 at the other side of the fold line when the core is folded.
  • each knockout section 27 is formed by a plurality of cuts 28 which are connected together by short uncut sections 29 so that the knockout section can be displaced from the solid fiberjacket upon the application of pressure thereto.
  • the size and shape of the knockout 27 is substan tially the same as the large aperture 24 formed in the core.
  • each small aperture 23 in the core provides a shoulder 31 adjacent large aperture 24 in the core.
  • knockout 27 is displaced by pressure, it abuts shoulder 31.
  • a fastening member 32 such as a bolt or a screw
  • head 33 on the fastening member upon engagement with knockout section 27 will displace the same against shoulder 31.
  • the knockout section provides a washer for head 33 and leaves a recess, as shown in FIG. 9, to receive head 33 of the fastening member.
  • the skid is of rectangular oblong shape being considerably longer than its width and will of course vary in size depending upon the size of the object to be supported by the skid.
  • the skid is about 28% in. long, and about 6 in. wide with an overall thickness of about if; in.
  • the solid fiber paperboard jacket is formed from a sheet of point thickness, weighing about 300 lbs. per sq. ft; and the double wall corrugated board is formed of 42 lb. liner (per thousand sq. ft.) and 26 lb. corrugated mediums (per thousand sq. ft.
  • the substitute panel for lumber may be any desired shape; and it need not be provided with apertures for attaching the panel where for example, it is to be secured to a wall.
  • the outer faces of the panel are formed from the solid fiberboard jacket 41 enveloping and adhesively bonded to the faces of the corrugated paperboard core 42.
  • a paperboard panel having a core of a plurality of layers of corrugated paperboard and a solid paperboard sheet secured to said core, an apertured portion through said panel for receiving a fastening member for attachment to an object, said apertured portion including an enlarged opening in a corrugated layer adjacent said sheet communicating with a smaller opening to provide a shoulder, a knockout section in said sheet which when the fastening member is cinched to said object is displaced onto said shoulder by a head on the fastening member, and the displaced knockout section provides a washer and forms a countersunk recess for the head.
  • each side face of the core is adhesively bonded to a solid fiber paperboard sheet, and said knockout section is in one of said solid fiber sheets.
  • a connecting structure between an object, and a panel comprising a core of a plurality of layers of corrugated paperboard, a solid fiber paperboard sheet secured to said core, and an apertured portion through the panel, said apertured portion including an enlarged opening in a corrugated layer adjacent said sheet in communication with a smaller opening which provides a shoulder; a washer of material removed from said sheet in abutment with said shoulder; and a fastening member extending through said apertured portion and secured to said object, and fastening member having a head engaging said washer and which is positioned in a recess resulting from said material removed from said sheet.
  • a substantially rigid paperboard skid for attachment to an appliance to support the same comprising an oblong shaped panel having an inner core of a plurality of layers of corrugated paperboard, an outer jacket of solid fiber paperboard enveloping said core and secured thereto, and having a plurality of apertured portions for receiving fastening members for attachment of the skid to said appliance, each apertured portion including a knockout section in a side face of the solid fiber jacket which when the fastening member is cinched to said appliance is displaced from said face by a head on the fastening member, and the displaced knockout section provides a washer which forms a countersunk recess for the head.
  • a substantially rigid paperboard skid for attachment to an appliance to support the same comprising an oblong shaped panel having an inner core of a plurality of layers of corrugated paperboard with adjacent faces in engagement with each other and terminating in flat side edges extending lengthwise of the skid, an outer jacket of substantially rigid and relatively non-flexible solid fiber paperboard enveloping said core and adhesively bonded thereto; said jacket being folded about said core along spaced apart fold lines providing flat edge panels substantially the thickness of the core substantially congruent with said fiat side edges of the core, a full panel adhesively bonded to one side face of said core and partial panels adhesively bonded to the opposite side face of the core with their adjacent edges substantially abutting, and a plurality of spaced apart apertures extending through the skid between the ends thereof for receiving fastening members for attachment of the skid to the appliance.
  • corrugated paperboard comprises double wall corrugated paperboard having outer paper liners, a pair of corrugated mediums, and an intermediate liner between said corrugated mediums; and said double wall corrugated paperboard is severed except through an outer liner to provide a hinge which is folded to form four layers of corrugated medium.

Abstract

A paperboard panel substitute for lumber, particularly adapted for use as a skid for supporting an object, comprises a plurality of layers of corrugated paperboard forming an inner core, and an outer jacket of solid fiber paperboard enveloping the core and secured thereto. The solid fiber jacket is formed by folding a sheet thereof about the core and adhesively bonding the same thereto. For use as a supporting skid, the panel is pre-formed with an apertured portion to receive a fastening member adapted to be secured to an object to be supported. Such apertured portion includes a knockout section which is displaced by a head on the fastening member to form a countersunk recess and a washer therefor.

Description

tent
[ 51 Mar. 14, 1972 [54] PAPERBOARD PANEL SUBSTITUTE FOR LUMBER [72] Inventor:
[73] Assignee: Crown Zellerbach Corporation, San Francisco, Calif.
[22] Filed: Apr. 13, 1970 [21] Appl.No.: 27,840
Gary L. Wagner, Covington, La.
2,728,545 12/1955 Hermitage ..108/56 3,436,045 4/1969 Anspaugh ..248/1 19 R 3,026,078 3/1962 Simkins 108/56 FOREIGN PATENTS OR APPLICATIONS 1,144,715 3/1969 Great Britain ..l08/51 Primary Examiner-Chancellor E. Harris Att0rneyStanley Bialos, Corwin R. Horton and William K. Quarles [57] ABSTRACT A paperboard panel substitute for lumber, particularly adapted for use as a skid for supporting an object, comprises a plurality of layers of corrugated paperboard forming an inner core, and an outer jacket of solidfiber paperboard enveloping the core and secured thereto. The solid fiber jacket is formed by folding a sheet thereof about the core and adhesively bonding the same thereto. For use as a supporting skid, the panel is pre-formed with an apertured portion to receive a fastening member adapted to be secured to an object to be supported. Such apertured portion includes a knockout section which is displaced by a head on the fastening member to form a countersunk recess and a washer therefor.
8 Claims, 13 Drawing Figures PATENTEUMAR 14 m2 SHEEI 2 [IF 2 2% w. mafia awn /nvK IA a W PAPERBOARD PANEL SUBSTITUTE FOR LUMBER SUMMARY AND OBJECTS Summarizing the invention, it provides a strong rigid panel which can be employed in many environments as a substitute for lumber, and which is particularly adapted as a substitute for wood slats or skids now commonly employed for attachment to various forms of household appliances to provide firm support therefor in containers for such appliances. The core is formed of a plurality of layers of corrugated paperboard, and advantageously the core has at least four overlying layers of corrugated medium with liners adhesively bonded thereto.
Double wall corrugated paperboard which consists of two layers of corrugated medium, having outer liners and an intermediate liner, is desirably employed. A plurality of congruent layers of such double wall corrugated paperboard may be placed one above the other to provide the core but it is advantageous and desirable to form the core by severing a sheet of double wall corrugated board medially thereof except through one of the outer liners, and to fold the same about the unsevered liner to provide at least four layers of corrugated medium secured to liners.
The entire core is enveloped by a strong jacket formed of relatively heavy solid fiber paperboard which is relatively rigid. A pair of spaced apart double fold lines is provided on the solid fiberboard sheet, which when the sheet is folded about the core form edge walls engaging side edges of the core and which are of substantially the thickness of the core, and also a full panel secured to one side face of the core, and partial panels secured to the opposite side face of the core with their adjacent edges in substantial abutment. In this connection the flutes and ridges of the corrugations of the core are desirably arranged to extend transversely of the length of the panel.
The panel thus formed is a substitute for lumber. It can be used to replace plywood and other forms of lumber parcels, and is particularly adapted to provide a support skid for objects. It can be sawed, and nailed to surfaces as with lumber, and screws can be readily fastened thereto. Moreover, it has the advantages over lumber is not splintering, shrinking or warping, and being without knots that can break out. Also it can be made much lighter than wood of comparable strength, and is more resilient than lumber. Hence, it will absorb shocks more readily; the latter being of particular advantage for use as a skid for supporting household appliances because it will not splinter into pieces that might scratch enameled surfaces ofsuch appliances.
For use as a supporting skid, the panel is preformed with at least one apertured portion to receive a fastening member for attachment to the appliance. The apertured portion includes an enlarged opening in a corrugated layer adjacent the solid fiber outer sheet, which communicates with smaller openings through the panel to thus form a shoulder. A knockout section substantially the size and shape of the enlarged opening, is formed in the solid fiber sheet over the enlarged opening. When the fastening member is screwed or cinched onto the object to which the panel is to be secured, the head thereon causes displacement of the knockout section onto the shoulder. As a result the displaced knockout section provides a washer for the head, and leaves a countersunk recess for receiving the head.
From the preceding it is seen that the invention has as its objects among others, the provision of an improved lumber substitute panel particularly adapted for use as a skid for supporting a household appliance in a shipping container, which is economical to manufacture, strong and rigid, is provided with improved means for securing the panel, and which at the same time has the advantages of wood in being able to be sawed and receive fastening members, and yet none of the disadvantages of warping, splintering, and knots that can be displaced. Other objects will become apparent from the following more detailed description and accompanying drawings in which:
DESCRIPTION OF DRAWINGS FIG. 1 is a plan view of a sheet of double wall corrugated paperboard for forming the core of a panel particularly adapted for use as a supporting skid; the view being broken away to shorten the same;
FIG. 2 is a similar plan view but illustrating the sheet of FIG. 1 folded into two congruent layers;
FIG. 3 is a plan view of the outer solid fiber jacket before it is folded about and secured to the core;
FIG. 4 is a transverse sectional exploded view of the core, and the jacket in a position to be folded about the core; the plane of the section being indicated by lines 5-5 in FIGS. 2 and 3;
FIG. 5 is a transverse sectional view of the assembled completed panel; the plane of the section being also indicated by the lines 5-5 in FIGS. 2 and 3;
FIG. 6 is an enlarged fragmentary plan view of the outer solid fiberboard jacket, illustrating a knockout section formed therein;
. FIG. 7 is an isometric view of a pair of panels secured to a household appliance (shown in phantom lines) to provide skid supports therefor;
FIG. 8 is an enlarged transverse fragmentary section taken in a plane indicated by line 88 in FIG. 7, and illustrating a fastening member before it is cinched onto the appliance;
FIG. 9 is a section similar to FIG. 8 but illustrating the fastening member cinched, and the knockout section in the solid fiberboard jacket displaced therefrom;
FIG. 10 is an enlarged transverse sectional view taken in a plane indicated by line 10-10 in FIG. 7;
FIG. 11 is an enlarged fragmentary longitudinal section taken in a plane indicated by line 11-11 in FIG. 7, and illustrating adhesive applied to the raw ends of the panel to moisture proof the same by preventing wicking of water therethrough;
FIG. 12 is a plan view of an unapertured panel which may be employed as a wall panel, or as a substitute for plywood; and
FIG. 13 is a fragmentary transverse section taken in a plane indicated by line 13-13 in FIG. 12.
DETAILED DESCRIPTION The panel hereof which has been advantageously employed as a substitute for a flat oblong lumber skid in supporting a household appliance during shipment in a container, is illustrated in FIGS. 1 through 11, and comprises a core 2 of a plurality of layers of corrugated paperboard. A jacket 3 of heavy solid fiber paperboard completely envelopes the core, being secured thereto by a suitable adhesive. Such jacket comprises a full panel 4, as can be seen best from FIG. 10, adhesively secured to one side face of the core, a pair of partial panels 6, each substantially half the width of the full panel, adhesively bonded to the opposite side face of the core with their adjacent edges substantially in abutment at 7, and edge walls 8 engaging the lateral edges of core 2.
For forming the jacket which is folded about the core, it is provided (FIG. 3) with a pair of longitudinally extending spaced apart double hinge or fold lines 9 obtained by scoring the sheet, with the fold lines of each pair spaced substantially the thickness of the core to provide such edge walls 8 of substantially the same thickness. To enhance rigidity, the sheet for jacket 3 is of solid fiber paperboard which as is well known in the industry, is formed by laminating two or more sheets of solid non-corrugated paperboard together to provide a solid fiber board of desired thickness (caliper) and weight. A suitable caliper and weight for the purpose hereof is between about 60 to point (0.060 to 0.100 in.) which will vary in weight from about 220 to 375 lbs. per thousand sq. ft. Solid fiber board of this character is very rigid and relatively nonfiexible, and the edge walls 8 of the panel will, therefore, form strong beams resistant to bending forces.
Regarding corrugated paperboard core 2, any suitable number of corrugated layers may be employed. Ad-
vantageously, the core is formed of at least four layers of cor rugated medium overlying each other respectively, and of congruent shape substantially the same congruent shape and size as full panel 4 of the jacket between the inner fold lines 9. Conventional so-called double wall corrugated paperboard is desirable, which in unfolded condition comprises two layers of conventional paperboard corrugated medium 11 each adhesively bonded to an outer facing liner sheet 12 and to an intermediate liner 12 as can be seen best from the enlarged views ofFIGS. l and 11.
These layers of corrugated paperboard may be provided by separate pieces of corrugated paperboard but it is advantageous to employ a unitary sheet, as shown in FIG. l, which is folded along a longitudinally extending center line to provide a core of oblong (rectangular) shape shown in FIG. 2. For such folding, the double wall corrugated sheet is severed by slitting along center line 13 (FIG. ll) all the way through except through one outer liner l2, and is then completely folded as shown in FIG. 2 and in enlarged FIG. 10, along such unsevered portion of the outer liner, which thus provides a hinge connection, with the adjacent faces of the folded double wall corrugated board in engagement.
These adjacent faces may have adhesive applied thereto so as to secure them together but this is not necessary. By severing the board in the manner described, and leaving one outer liner as a hinge connection at 13 for the folding, it will be noted from FIGS. 9 and 10 that the side edge of the core at the fold line becomes automatically substantially even without material bulging so as to enable the solid fiber jacket to tightly embrace core 2.
The double wall corrugated paperboard may be of any conventional weight commonly employed known in the industry. A suitable weight for the corrugated medium hereof is about 26 to 33 lbs. per thousand sq. ft. with liners varying in weight from about 30 to 50 lbs. per thousand sq. ft., although this is not critical as liners as high as 90 lbs. per thousand sq. ft have been employed. A suitable weight for skid use is about 26 lbs. per thousand sq. ft. for the corrugated medium, and about 42 lbs. per thousand sq. ft. for the liners, which provides a Mullen test of about 350 lbs. As will be best noted from FIGS. 10 and 11 corrugated paperboard core 2 is so severed and folded that the corrugations and the flutes thereof run transversely with respect to the axial length of the panel.
In forming the panel, as can be seen from FIGS. 4 and 5, the sheet for inner core 2 is folded along fold line 13 to bring the adjacent faces of the double wall corrugated board into engagement; and then with adhesive (indicated at 15 in FIG. 11) applied to the inside face of the sheet for jacket 3, it is folded with full panel 4 positioned over one face of the core and folded along the fold lines 9 to engage edge walls 8 with the side edges of the core and partial panels 6 with the opposite face of the core. When thus assembled, the panel is then passed through conventional compression rollers in a conventional manner to apply pressure and thus effect firm adhesive bonding of the jacket to the core.
With respect to the adhesive, conventional starch adhesive commonly employed in the industry may be used and is preferred. However, any other type of adhesive may be employed, such as thermoplastic or thermosetting resins, and hot melt adhesives. To moisture proof the ends of the panel after the bond has been formed between the core and the jacket, they are coated with moisture proofing material, either by spray or dipping, such as molten wax or plastic material, as is indicated at 14 in FIG. 11.
For use as a skid to support firmly a household appliance 21 such as a refrigerator, TV set, stove or washing machine, shown in phantom lines in FIG. 7, for the purpose of preventing damage to both a paperboard container or the appliance in which it is generally packaged for shipment, the skid is formed with apertured portions 22 to receive fastening members, as is shown in FIGS. 8 and 9. These apertured portions are formed by providing sets of apertures in both the core and the jacket of the panel before they are assembled together. As can be seen from FIGS. 1 through 3, small apertures 23 are formed in the parent core sheet adjacent one side of fold line l3. They register with large apertures 24 at the other side of the fold line when the core is folded.
Small apertures 26 are formed in the full panel 4 of the jacket; and adjacent to such apertures, knockout sections 27 are formed in a partial panel 6 of the jacket. Referring to FIG. 6, it will be noted that each knockout section 27 is formed by a plurality of cuts 28 which are connected together by short uncut sections 29 so that the knockout section can be displaced from the solid fiberjacket upon the application of pressure thereto. The size and shape of the knockout 27 is substan tially the same as the large aperture 24 formed in the core.
With particular reference to FIGS. 8 and 9, it will be noted that the material about each small aperture 23 in the core provides a shoulder 31 adjacent large aperture 24 in the core. As a result when knockout 27 is displaced by pressure, it abuts shoulder 31. Thus, when a fastening member 32, such as a bolt or a screw, is cinched tightly to the appliance support, as shown in FIG. 7, head 33 on the fastening member upon engagement with knockout section 27 will displace the same against shoulder 31. This results in a connection in which the knockout section provides a washer for head 33 and leaves a recess, as shown in FIG. 9, to receive head 33 of the fastening member.
The skid is of rectangular oblong shape being considerably longer than its width and will of course vary in size depending upon the size of the object to be supported by the skid. In the embodiment of the invention illustrated, the skid is about 28% in. long, and about 6 in. wide with an overall thickness of about if; in. The solid fiber paperboard jacket is formed from a sheet of point thickness, weighing about 300 lbs. per sq. ft; and the double wall corrugated board is formed of 42 lb. liner (per thousand sq. ft.) and 26 lb. corrugated mediums (per thousand sq. ft.
As is illustrated in FIG. 12 and 13, the substitute panel for lumber may be any desired shape; and it need not be provided with apertures for attaching the panel where for example, it is to be secured to a wall. In FIG. 13, it will be noted that the outer faces of the panel are formed from the solid fiberboard jacket 41 enveloping and adhesively bonded to the faces of the corrugated paperboard core 42.
lclaim:
1. In a paperboard panel having a core of a plurality of layers of corrugated paperboard and a solid paperboard sheet secured to said core, an apertured portion through said panel for receiving a fastening member for attachment to an object, said apertured portion including an enlarged opening in a corrugated layer adjacent said sheet communicating with a smaller opening to provide a shoulder, a knockout section in said sheet which when the fastening member is cinched to said object is displaced onto said shoulder by a head on the fastening member, and the displaced knockout section provides a washer and forms a countersunk recess for the head.
2. The paperboard panel of claim 1 wherein each side face of the core is adhesively bonded to a solid fiber paperboard sheet, and said knockout section is in one of said solid fiber sheets.
3. A connecting structure between an object, and a panel comprising a core of a plurality of layers of corrugated paperboard, a solid fiber paperboard sheet secured to said core, and an apertured portion through the panel, said apertured portion including an enlarged opening in a corrugated layer adjacent said sheet in communication with a smaller opening which provides a shoulder; a washer of material removed from said sheet in abutment with said shoulder; and a fastening member extending through said apertured portion and secured to said object, and fastening member having a head engaging said washer and which is positioned in a recess resulting from said material removed from said sheet.
4. A substantially rigid paperboard skid for attachment to an appliance to support the same comprising an oblong shaped panel having an inner core of a plurality of layers of corrugated paperboard, an outer jacket of solid fiber paperboard enveloping said core and secured thereto, and having a plurality of apertured portions for receiving fastening members for attachment of the skid to said appliance, each apertured portion including a knockout section in a side face of the solid fiber jacket which when the fastening member is cinched to said appliance is displaced from said face by a head on the fastening member, and the displaced knockout section provides a washer which forms a countersunk recess for the head.
5. A substantially rigid paperboard skid for attachment to an appliance to support the same comprising an oblong shaped panel having an inner core of a plurality of layers of corrugated paperboard with adjacent faces in engagement with each other and terminating in flat side edges extending lengthwise of the skid, an outer jacket of substantially rigid and relatively non-flexible solid fiber paperboard enveloping said core and adhesively bonded thereto; said jacket being folded about said core along spaced apart fold lines providing flat edge panels substantially the thickness of the core substantially congruent with said fiat side edges of the core, a full panel adhesively bonded to one side face of said core and partial panels adhesively bonded to the opposite side face of the core with their adjacent edges substantially abutting, and a plurality of spaced apart apertures extending through the skid between the ends thereof for receiving fastening members for attachment of the skid to the appliance.
6. The skid of claim 5 wherein said solid fiber paperboard of the outer jacket is about 60 to point in thickness weighing about 220 to 375 pounds per thousand square feet.
7. The skid of claim 5 wherein said corrugated paperboard comprises double wall corrugated paperboard having outer paper liners, a pair of corrugated mediums, and an intermediate liner between said corrugated mediums; and said double wall corrugated paperboard is severed except through an outer liner to provide a hinge which is folded to form four layers of corrugated medium.
8. The skid of claim 5 wherein said solid fiber paperboard for the outer jacket is about 60 to 100 point in thickness weighing about 220 to 375 pounds per thousand square feet, and the ends of the skid are coated with moisture proofing material.

Claims (8)

1. In a paperboard panel having a core of a plurality of layers of corrugated paperboard and a solid paperboard sheet secured to said core, an apertured portion through said panel for receiving a fastening member for attachment to an object, said apertured portion including an enlarged opening in a corrugated layer adjacent said sheet communicating with a smaller opening to provide a shoulder, a knockout section in said sheet which when the fastening member is cinched to said object is displaced onto said shoulder by a head on the fastening member, and the displaced knockout section provides a washer and forms a countersunk recess for the head.
2. The paperboard panel of claim 1 wherein each side face of the core is adhesively bonded to a solid fiber paperboard sheet, and said knockout section is in one of said solid fiber sheets.
3. A connecting structure between an object, and a panel comprising a core of a plurality of layers of corrugated paperboard, a solid fiber paperboard sheet secured to said core, and an apertured portion through the panel, said apertured portion including an enlarged opening in a corrugated layer adjacent said sheet in communication with a smaller opening which provides a shoulder; a washer of material removed from said sheet in abutment with said shoulder; and a fastening member extending through said apertured portion and secured to said object, said fastening member having a head engaging said washer and which is positioned in a recess resulting from said material removed from said sheet.
4. A substantially rigid paperboard skid for attachment to an appliance to support the same comprising an oblong shaped panel having an inner core of a plurality of layers of corrugated paperboard, an outer jacket of solid fiber paperboard enveloping said core and secured thereto, and having a plurality of apertured portions for receiving fastening members for attachment of the skid to said appliance, each apertured portion including a knockout section in a side face of the solid fiber jacket which when the fastening member is cinched to said appliance is displaced from said face by a head on the fastening member, and the displaced knockout section provides a washer which forms a countersunk recess for the head.
5. A substantially rigid paperboard skid for attachment to an appliance to support the same comprising an oblong shaped panel having an inner core of a plurality of layers of corrugated paperboard with adjacent faces in engagement with each other and terminating in flat side edges extending lengthwise of the skid, an outer jacket of substantially rigid and relatively non-flexible solid fiber paperboard enveloping said core and adhesively bonded thereto; said jacket being folded about said core along spaced apart fold lines providing flat edge panels substantially the thickness of the core substantially congruent with said flat side edges of the core, a full panel adhesively bonded to one side face of said core and partial panels adhesively bonded to the opposite side face of the core with their adjacent edges substantially abutting, and a plurality of spaced apart apertures extending through the skid between the ends thereof for receiving fastening members for attachment of the skid to the appliance.
6. The skid of claim 5 wherein said solid fiber paperboard of the outer jacket is about 60 to 100 point in thickness weighing about 220 to 375 pounds per thousand square feet.
7. The skid of claim 5 wherein said corrugated paperboard comprises double wall corrugated paperboard having outer paper liners, a pair of corrugated mediums, and an intermediate lineR between said corrugated mediums; and said double wall corrugated paperboard is severed except through an outer liner to provide a hinge which is folded to form four layers of corrugated medium.
8. The skid of claim 5 wherein said solid fiber paperboard for the outer jacket is about 60 to 100 point in thickness weighing about 220 to 375 pounds per thousand square feet, and the ends of the skid are coated with moisture proofing material.
US27840A 1970-04-13 1970-04-13 Paperboard panel substitute for lumber Expired - Lifetime US3648959A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US2784070A 1970-04-13 1970-04-13

Publications (1)

Publication Number Publication Date
US3648959A true US3648959A (en) 1972-03-14

Family

ID=21840081

Family Applications (1)

Application Number Title Priority Date Filing Date
US27840A Expired - Lifetime US3648959A (en) 1970-04-13 1970-04-13 Paperboard panel substitute for lumber

Country Status (2)

Country Link
US (1) US3648959A (en)
CA (1) CA951627A (en)

Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3891170A (en) * 1974-08-19 1975-06-24 Gen Electric Shipping skid
US3907241A (en) * 1973-09-07 1975-09-23 Whirlpool Co Disposable skid
US3921279A (en) * 1974-08-20 1975-11-25 Thomas G Daley Method for making a support for an object
US4030187A (en) * 1976-05-27 1977-06-21 Daley Thomas G Method of making an object support member
US4241892A (en) * 1979-08-31 1980-12-30 Boone Box Co. Appliance skidboard and method of making
US4852735A (en) * 1988-09-07 1989-08-01 Maytag Corporation Breakaway crate base
US6022178A (en) * 1998-07-20 2000-02-08 The Aerospace Corporation Flexure washer bearing and method
US6155527A (en) * 1997-09-16 2000-12-05 Sonoco Development, Inc. Appliance base pad
US6765950B1 (en) * 1999-04-01 2004-07-20 Custom One Design, Inc. Method for spread spectrum communication of supplemental information
US20050103964A1 (en) * 2003-11-17 2005-05-19 Sonoco Development, Inc. Tubular structure for supporting a product
US20060243615A1 (en) * 2005-04-29 2006-11-02 Moskwa Kenneth R Boiler shipping apparatus and method
US20110095157A1 (en) * 2009-10-23 2011-04-28 Sonoco Development, Inc. Shipping base with locator pins
US20160347024A1 (en) * 2015-05-26 2016-12-01 Carcoustics Techconsult Gmbh Material composition for the production of a stiffening member for lightweight construction, method for producing a stiffening member for lightweight construction and stiffening member for lightweight construction
US20180134445A1 (en) * 2016-11-14 2018-05-17 Haier Us Appliance Solutions, Inc. Multi-density skid assembly
US10328655B2 (en) 2014-10-30 2019-06-25 Erdie End Caps, Llc Paper-based elongate structures suitable for use as lumber substitutes
US20200196758A1 (en) * 2016-03-25 2020-06-25 Paul J. Segas Seismic base isolation system for barrel racks

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1975906A (en) * 1933-12-11 1934-10-09 Charles A Stewart Cloth board
US2215241A (en) * 1939-01-23 1940-09-17 Weston Paper And Mfg Company Insulating board and plaster base
US2280080A (en) * 1939-11-13 1942-04-21 Nicholas A Predan Concrete insert
US2633982A (en) * 1949-07-14 1953-04-07 Addison Semmes Corp Shipping package and pallet means
US2728545A (en) * 1952-12-29 1955-12-27 William R Hermitage Materials handling pallet
US3026078A (en) * 1958-06-05 1962-03-20 Continental Can Co Collapsible and expendable pallet
GB1144715A (en) * 1967-03-04 1969-03-05 Hay S Internat Services Birmin An expendable pallet
US3436045A (en) * 1967-07-10 1969-04-01 Gen Motors Corp Appliance leveling foot and shipping pallet bolt

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1975906A (en) * 1933-12-11 1934-10-09 Charles A Stewart Cloth board
US2215241A (en) * 1939-01-23 1940-09-17 Weston Paper And Mfg Company Insulating board and plaster base
US2280080A (en) * 1939-11-13 1942-04-21 Nicholas A Predan Concrete insert
US2633982A (en) * 1949-07-14 1953-04-07 Addison Semmes Corp Shipping package and pallet means
US2728545A (en) * 1952-12-29 1955-12-27 William R Hermitage Materials handling pallet
US3026078A (en) * 1958-06-05 1962-03-20 Continental Can Co Collapsible and expendable pallet
GB1144715A (en) * 1967-03-04 1969-03-05 Hay S Internat Services Birmin An expendable pallet
US3436045A (en) * 1967-07-10 1969-04-01 Gen Motors Corp Appliance leveling foot and shipping pallet bolt

Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3907241A (en) * 1973-09-07 1975-09-23 Whirlpool Co Disposable skid
US3891170A (en) * 1974-08-19 1975-06-24 Gen Electric Shipping skid
US3921279A (en) * 1974-08-20 1975-11-25 Thomas G Daley Method for making a support for an object
US4030187A (en) * 1976-05-27 1977-06-21 Daley Thomas G Method of making an object support member
US4241892A (en) * 1979-08-31 1980-12-30 Boone Box Co. Appliance skidboard and method of making
US4852735A (en) * 1988-09-07 1989-08-01 Maytag Corporation Breakaway crate base
US6155527A (en) * 1997-09-16 2000-12-05 Sonoco Development, Inc. Appliance base pad
US6022178A (en) * 1998-07-20 2000-02-08 The Aerospace Corporation Flexure washer bearing and method
US6765950B1 (en) * 1999-04-01 2004-07-20 Custom One Design, Inc. Method for spread spectrum communication of supplemental information
US20050103964A1 (en) * 2003-11-17 2005-05-19 Sonoco Development, Inc. Tubular structure for supporting a product
US7028964B2 (en) 2003-11-17 2006-04-18 Sonoco Development, Inc. Tubular structure for supporting a product
US20060243615A1 (en) * 2005-04-29 2006-11-02 Moskwa Kenneth R Boiler shipping apparatus and method
US20110095157A1 (en) * 2009-10-23 2011-04-28 Sonoco Development, Inc. Shipping base with locator pins
US8671849B2 (en) * 2009-10-23 2014-03-18 Sonoco Development, Inc. Shipping base with locator pins
US10328655B2 (en) 2014-10-30 2019-06-25 Erdie End Caps, Llc Paper-based elongate structures suitable for use as lumber substitutes
US20160347024A1 (en) * 2015-05-26 2016-12-01 Carcoustics Techconsult Gmbh Material composition for the production of a stiffening member for lightweight construction, method for producing a stiffening member for lightweight construction and stiffening member for lightweight construction
US20200196758A1 (en) * 2016-03-25 2020-06-25 Paul J. Segas Seismic base isolation system for barrel racks
US20180134445A1 (en) * 2016-11-14 2018-05-17 Haier Us Appliance Solutions, Inc. Multi-density skid assembly
US10414543B2 (en) * 2016-11-14 2019-09-17 Haier Us Appliance Solutions, Inc. Multi-density skid assembly

Also Published As

Publication number Publication date
CA951627A (en) 1974-07-23

Similar Documents

Publication Publication Date Title
US3648959A (en) Paperboard panel substitute for lumber
US9663267B2 (en) Shipping pallet apparatus and method
US5433156A (en) Construction of pallets from corrugated sheet material
US4580380A (en) Composite filled interior structural box beams
EP0086789B1 (en) Freight pallet
US2882990A (en) Sound absorbing units and method of making same
US4390580A (en) High pressure laminate for access floor panels
US3709425A (en) Shipping carton and end panel construction therefor
US4765535A (en) Decorative package with simulated overwrap
US3072313A (en) Figure 4 corner post
HU216375B (en) Pallet made of cardboard
US3135228A (en) Pallet construction
US5463965A (en) Paperboard support structure for supporting a load
US6241148B1 (en) Polygon-shaped container
US5799861A (en) Case forming materials and components and structures thereof
US5674593A (en) Structural laminate with corrugated core and related method
US20080060319A1 (en) Lightweight Structural Panel And Method For Making Same
US3559867A (en) Multi-ply container
US3905478A (en) Container construction and end panel therefor
US2336852A (en) Method of making flexible blanks
US2108479A (en) Nonshrinkable wood panel
GB2368074A (en) Corrugated board
JPS58500975A (en) Original products for coffins and coffins made from these products
US3838602A (en) Reinforced reel
US3099969A (en) Load bearing industrial pallet

Legal Events

Date Code Title Description
AS Assignment

Owner name: GAYLORD CONTAINER LIMITED, ONE BUSH STREET, SAN FR

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST. SUBJECT TO CONDITIONS RECITED;ASSIGNOR:CROWN ZELLERBACH CORPORATION, A CORP OF NV.;REEL/FRAME:004610/0457

Effective date: 19860429

AS Assignment

Owner name: BANKERS TRUST COMPANY, A NY BANKING CORP.

Free format text: SECURITY INTEREST;ASSIGNOR:GAYLORD CONTAINER CORPORATION, A CORP. OF DE;REEL/FRAME:004922/0959

Effective date: 19880329

AS Assignment

Owner name: GAYLORD CONTAINER CORPORATION

Free format text: CHANGE OF NAME;ASSIGNOR:GC ACQUISITION CORPORATION;REEL/FRAME:004941/0061

Effective date: 19861203

Owner name: GAYLORD CONTAINER CORPORATION

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:GAYLORD CONTAINER LIMITED;REEL/FRAME:004941/0056

Effective date: 19861117