Installation for the assembly of a cardboard pallet

Abstract

The invention describes an installation comprising: a plurality of forming modules (C1-C5), wherein in some of the forming modules (C) pallet elements are moved in a second direction (D2); and transfer modules (T1-T4) arranged between the forming modules (C1-C5), joining them to one another, and configured to transfer the pallet between each forming module (C1-C5) once the action of the corresponding forming module has been completed. The pallet is formed by being moved in a feed direction corresponding to a first direction (D1) transverse to second directions (D2) in which the pallet-forming elements (C) are moved through the forming modules.

Description

[0001] INSTALLATION FOR ASSEMBLING A CARDBOARD PALLET

[0002] DESCRIPTION

[0003] OBJECT OF THE INVENTION

[0004] The present invention falls within the technical field of manufacturing cardboard loading platforms. Specifically, it describes an installation for assembling a cardboard pallet, and more specifically, the installation allows the complete assembly of a cardboard pallet comprising a plurality of different elements (sheets, inserts, complementary notches, reinforcements, etc.).

[0005] The key to the installation are the forming modules, which are the means of loading and feeding the different elements of the pallet, configured for the positioning of the inserts, the positioning of the cardboard sheets, the positioning of the crossbeams, as well as the final application of various specific finishes depending on the type of pallet to be assembled.

[0006] TECHNICAL PROBLEM TO BE SOLVED AND BACKGROUND OF THE INVENTION

[0007] Machines are currently available for assembling classic wooden pallets made up of crossbeams and slats fastened together by nailing. For example, document ES2027487 describes an automatic, one-way pallet nailing machine. It includes feeding mechanisms for the wooden crossbeams and for feeding the slats that are nailed together. The machine also has nail guns and a mechanism for turning the resulting structure, after nailing the slats to the crossbeams, to feed additional slats onto the opposite side and nail them in place to complete the pallet assembly.

[0008] This is a highly complex machine (requiring feeding, nailing, positioning, and tilting mechanisms, among others) specifically designed for assembling wooden pallets and unsuitable for assembling pallets made with cardboard stringers and crossbeams. The significant rise in environmental awareness is generating a growing demand for next-generation cardboard pallets. These pallets comprise multiple components, making them structurally more complex, but in return, they are far more widely used than traditional cardboard pallets. This increasing demand has created a need for state-of-the-art cardboard pallet assembly equipment that enables optimal assembly.

[0009] Until now, these stronger and more complex pallets have been assembled manually. This increases their cost and also results in very low volumes of pallets assembled per unit of time, preventing them from competing on equal terms with plastic or wooden loading platforms.

[0010] A currently known solution for assembling cardboard pallets is described in document ES2260987, which proposes a pallet assembly machine designed to form cardboard pallets. This machine includes storage, feeding, and dosing means for stringers, and for crossbeams, located in designated areas. The stringers are positioned longitudinally on their edges, and the corresponding crossbeams are attached transversely. Both the stringers and crossbeams have complementary notches for interlocking. The stringers move on guides and are positioned in an area where the crossbeams drop in and are pushed vertically by a pusher to perform the upper assembly of the crossbeams onto the stringers, which have been previously and properly positioned in the area.

[0011] Document EP0544414 is also known, describing a lightweight corrugated cardboard pallet and an apparatus and method for its assembly. The pallet has longitudinally extending, spaced members that intersect laterally by means of interlocking notches aligned with the transverse members. These members have cutouts forming channels to receive points for the spikes of a lifting installation. The spike lifting points are completely continuous horizontally extending panels with additional support panels that increase the width of the lifting point. Each member is slotted on one side only and folded symmetrically inward to form a solid core of corrugated cardboard panels.Also known is document FR2672001 which proposes an installation with a first assembly intended to make the upper surface of a pallet and its positioning and fixing on some blocks, and a second assembly intended to make the support base on the ground and for its positioning and fixing to the blocks, both assemblies being separated from each other by a pallet inversion device.

[0012] DESCRIPTION OF THE INVENTION

[0013] The installation that is the subject of this invention is designed to assemble pallets whose structure is made entirely of cardboard, allowing the assembly of all its components or parts without the need for additional fasteners. This invention provides an assembly installation that allows for the complete assembly of the cardboard pallet in a simple, efficient, and high-performance manner compared to other systems or installations currently known.

[0014] Specifically, the invention's installation allows for the assembly of all pallet components with varying final qualities of mechanical strength, chemical resistance, moisture resistance, etc. Furthermore, it is a fully modular system. This means that by simply modifying the central modules of the installation, which are responsible for placing reinforcing laminate inserts into the pallet, pallets with different levels of mechanical strength can be assembled.

[0015] Preferably, the pallets to be assembled in the installation of the invention are foldable cardboard pallets. More specifically, these pallets comprise a sheet forming the lower base, vertical support elements (inserts), at least one reinforcing element (which may be, for example, a reinforcing sheet), and a sheet forming the upper base.

[0016] In one embodiment, the sheet forming the lower base comprises double-walled horizontal support flaps and vertical support flaps that are folded to contact the outer wall of the inserts. These inserts are formed from foldable cardboard sheets and are either vertical perimeter support members or internal support members. The pallet comprises at least one reinforcing element, which may be, for example, a reinforcing sheet with vertical support flaps that are folded to contact and secure against the inner wall of the inserts. There may also be another reinforcing element, which may be another reinforcing sheet to provide additional structural support and which may be formed, for example, from honeycomb cardboard.The pallet also comprises a sheet forming the upper base and which may comprise perimetrical fins respectively folded to come into contact and be secured against the outer wall of the inserts, and wherein the folded perimetrical fins define inlets for inserting the fork of a forklift.

[0017] The new facility allows the assembly of cardboard pallets of the type in question, adapting to all possible variations.

[0018] BRIEF DESCRIPTION OF THE FIGURES

[0019] To complete the description and to aid in a better understanding of the characteristics of the invention, this descriptive document is accompanied, as an integral part thereof, by a set of drawings in which, for illustrative and non-limiting purposes, the following has been represented:

[0020] Figure 1 represents a view of the installation of the invention and also shows, in relation to each forming module, how the forming of the pallet evolves with the different elements that make it up.

[0021] Figures 2A-C represent, respectively, examples of the installation adapted to the assembly of different types of pallets, depending on the number and type of reinforcement element to be placed on the pallet.

[0022] Figure 3 represents a perspective view of a forming module of the installation.

[0023] DETAILED DESCRIPTION

[0024] The present invention is not limited to the embodiment described herein. Other configurations may be realized by those skilled in the art in light of this description. Accordingly, the scope of the invention is defined by the following claims.

[0025] Figure 1 illustrates the installation of the invention. As can be seen in this figure, the installation is configured longitudinally in a first direction (D1) that corresponds to the direction of pallet movement through the different forming modules (C1-C5). These modules, in turn, are configured longitudinally in a second direction (D2), where this second direction (D2) is transverse to the first direction (D2).

[0026] Between each pair of forming modules (C1-C5) there is a transfer module (T1-T4) configured to transfer the pallet between the ends of each forming module (C1-C5) once the action of the corresponding forming module is completed.

[0027] The forming modules (C1-C5) are stations for forming and joining the elements that make up the cardboard pallet. Preferably, the arrangement of these forming modules is as follows:

[0028] -Forming module 1 (C1): It is a module configured to receive sheets (1) of cardboard, completely flat, and fold said sheets (1) to form the lower base (1') or the skids of the pallet.

[0029] - Forming Module 2 (C2): This module is configured to form and position a plurality of inserts (2) or columns in the designated areas between the lower base (1') of the pallet and the upper loading base (4) of the pallet (which has not yet been placed). These inserts (2) (or columns) are the elements configured to transmit the load between the pallet bases (lower base (1') and upper base (4)).

[0030] - Forming modules 3, 3', 3” (C3, C3', C3”): These modules are configured to hold reinforcing elements (3, 3', 3”) (which can be reinforcing sheets and / or reinforcing inserts) on the inserts (2). These elements distribute the load across the entire surface of the pallet, transferring it to the base as previously described. Therefore, the installation may include one or more of these forming modules 3, 4, 5, depending on the number or type of reinforcing elements (3, 3', 3”) to be used. It is important to note that the more reinforcing elements (3, 3', 3”) the pallet includes, the better its load-bearing capacity.

[0031] - Forming module 4 (C4): This module is configured to receive and place the upper loading base (4) of the pallet that covers and surrounds the inserts (2) and the reinforcing element (3) and any additional reinforcing elements (3', 3") placed in forming modules 2 and 3, 3', 3" (C2-C3").

[0032] - Forming Module 5 (C5): This module is configured to perform the final forming operations of the pallet. The pallet arrives at this module with all structural elements already positioned and joined together. Here, the desired finishes are applied, such as non-slip chemical coatings. Some parts are trimmed for better adaptation to the handling systems with which the pallet will be used, etc. This module may also include optical instruments for inspecting the suitability of the formed pallet. The formed pallets can be removed from the installation individually or in vertical stacks.

[0033] Figure 1 also shows, in relation to each forming module (C), how the pallet evolves from the sheet (1) with which the lower base (T) is formed to the complete pallet (5) already formed.

[0034] Figure 1 also shows the second directions (D2) of movement of the pallet elements in each forming module (C). The first direction (D1) of movement through the different forming modules (C) and the transfer modules (T) that connect them is also shown.

[0035] Figures 2A-C show examples of the installation adapted to the assembly of different types of pallets, depending on the number and type of reinforcement element (3, 3', 3") that will be placed on the pallet.

[0036] Logically, an installation sized for the placement of three reinforcing elements (3, 3', 3"), as shown in Figure 2C, would also allow the manufacture of pallets with only one reinforcing element (3). In this case, two of the corresponding forming modules would be disabled: forming module 3' (C3') and forming module 3" (C3"). Figure 3 shows one forming module (C), in this case, forming module 1 (C1). The structure of the forming modules (C) is similar in all cases (except for forming modules 2 and 5 (C2, C5)).

[0037] In forming module 5 (C5), the final forming operations are performed. In this module, a roller conveyor is used to move the fully formed pallet (5) in a second direction (D2), opposite to the direction of travel in the other forming modules (C1-C4). This is because the fully formed pallet (5) is removed from the installation in forming module 5 (C5). Similarly, if a defective formed pallet (5) is detected in forming module 5 (C5), it is also removed in the same manner and subsequently sent to a waste line. As previously mentioned, forming module 5 (C5) preferably includes an inspection system configured to inspect the formed pallet (5) and determine whether it meets certain quality requirements.

Claims

CLAIMS 1 Installation for assembling a cardboard loading platform characterized in that it comprises: - a plurality of forming modules (C1, C3, C3', C3”, C4, C5) and in each forming module (C1, C3, C3', C3”, C4, C5) pallet elements are moved in a second direction (D2); - a forming module 2 (C2), arranged between forming module 1 (C1) and forming module 3 (C3); - transfer modules (T1-T4) arranged between the forming modules (C1-C5), joining them together, and configured to transfer the pallet between the forming modules (C1-C5) once the action of the corresponding forming module is completed; such that the pallet is formed by moving along a direction of advance that corresponds to a first direction (D1) transverse to the second directions (D2), through the forming modules (C1-C5) and the transfer modules (T1-T4); and where: - the forming modules (C) comprise at least: -a forming module 1 (C1) in which sheets (1) are received with which a lower base (T) of the pallet (5) is formed; -a forming module 2 (C2) in which a plurality of inserts are placed (2) on the lower base (T); -a forming module 3 (C3) in which some reinforcing elements are placed (3) on the inserts (2); -a forming module 4 (C4) in which a sheet forming an upper base (4) of the pallet (5) is placed on the reinforcing elements (3); -a forming module 5 (C5) in which the final forming operations of the pallet (5) are carried out and from which the pallet (5) leaves the facility.

2. Installation according to claim 1 wherein at least one of the forming modules (C1, C2, C3, C3', C3”, C4, C5) comprises a roller transport system.

3. Installation according to any one of the preceding claims wherein the second directions (D2) are parallel to each other and the directions of displacement in said second directions (D2) coincide in the forming modules 1, 2, 3, 4 (C1, C2, C3, C4) and opposite them in the forming module 5 (C5). 4.- Installation according to any one of the preceding claims comprising a forming module 3' (C3') disposed between the forming module 2 (C2) and the forming module 4 (C4) and connected to them through transfer modules (T3, T3').

5. Installation according to claim 6 comprising a forming module 3” (C3”) disposed between the forming module C3’ (C3’) and the forming module (C4) and connected to them through transfer modules (T3”, T4).

6. Installation according to any one of the preceding claims wherein the forming module 5 (C5) comprises an inspection system configured to perform an inspection of the formed pallet (5).

Images