Methods for manufacturing an end-less pallet from less in width chain sheet material

1 . A method of manufacturing endless pallet chain sheet material, comprising steps of:

(a) providing a pallet having a longitudinal direction and a lateral direction perpendicular to the longitudinal direction;

(b) providing a chain sheet material;

(c) positioning the chain sheet material on the pallet to include a first row and a second row, wherein:

the first row and the second row are arranged along the lateral direction;

the first row is disposed at a layer the same as or below that disposed at by the second row;

each of the first row and the second row includes N bundles arranged along the longitudinal direction, wherein N≥2;

each of the N bundles includes an upper portion and a lower portion; and

(d) connecting the lower portion of a first bundle of the first row with the upper portion of an N-th bundle of the second row;

(e) connecting the upper portion of an n th bundle of the first row with the lower portion of an (n+1)th bundle of the first row, wherein n=1, 2, . . . N−1; and

(f) connecting the upper portion of the n th bundle of the second row with the lower portion of an (n+1)th bundle of the second row, wherein n=1, 2, . . . N−1.

2 . The method as claimed in claim 1 , wherein the lower portion of the first bundle of the first row includes a bottom sheet and the upper portion of the N-th bundle of the second row includes a top sheet.

3 . The method as claimed in claim 2 , wherein the lower portion of the first bundle of the first row includes:

a tail part including the bottom sheet of the first bundle of the first row and connected with the top sheet of the N-th bundle of the second row;

a first folded part connected with the upper portion of the first bundle of the first row;

a second folded part connected with the tail part; and

a middle part connected between the first folded part the second folded part with a length sufficient to put the second folded part on top of the first bundle of the second row.

4 . The method as claimed in claim 3 , wherein the step (d) further comprising:

(d1) putting the middle part and the tail part of the lower portion of the first bundle of the first row aside of the first folded part before step (e); and

(d2) putting the tail part of the lower portion of the first bundle of the first row above the first bundle of the first row before step (f).

5 . The method as claimed in claim 3 , wherein the step (d) further comprising:

(d3) turning over the top sheet of the N-th bundle of the second row; and

(d4) connecting the tail part of the lower portion of the first bundle of the first row with the top sheet of the N-th bundle of the second row on top of and between the first and N-th bundles of the second row.

6 . The method as claimed in claim 1 , wherein an arrangement direction extending from the first bundle to the N-th bundle of the first row is the same as that extending from the first bundle to the N-th bundle of the second row.

7 . The method as claimed in claim 1 , further comprising pre-processing the chain sheet material before positioning the chain sheet material on the pallet so that the chain sheet material has 1-ply pre-configured or pre-folded sheets, or 2-ply pre-configured or pre-folded sheets.

8 . A method of manufacturing endless pallet chain sheet material, comprising steps of:

(a) providing a pallet having a longitudinal direction and a lateral direction perpendicular to the longitudinal direction;

(b) providing a chain sheet material;

(c) positioning the chain sheet material on the pallet to include a first layer and a second layer above the first layer, wherein:

each of the first layer and the second layer includes M rows including a first row and a last row, wherein M≥2;

each of the M rows includes N bundles arranged along the longitudinal direction; and

each of the N bundles includes an upper portion and a lower portion; and

(d) connecting the lower portion of a first bundle of the M-th row at the second layer with the upper portion of an N-th bundle of the first row at the first layer.

9 . The method as claimed in claim 8 , wherein the lower portion of the first bundle of the last row at the second layer includes a bottom sheet and the upper portion of the last bundle of the first row at the first layer includes a top sheet.

10 . The method as claimed in claim 9 , further comprising step (e) sequentially disposing the first bundles of the M rows at the second layer along the lateral direction before step (d).

11 . The method as claimed in claim 10 , further comprising (f) sequentially connecting the upper portion of the n-th bundle of the m-th row with the lower portion of the (n+1)th bundle of the m-th row at the second layer after step (d), wherein n=1, 2, . . . N−1 and m=1, 2, . . . M.

12 . The method as claimed in claim 11 , wherein the lower portion of the first bundle of M-th row at the second layer includes:

a tail part including the bottom sheet of the first bundle of the M-th row at the second layer and connected with the top sheet of the N-th bundle of the first row at the first layer; and

a folded part connected between the tail part and the upper portion of the first bundle of the M-th row at the second layer.

13 . The method as claimed in claim 12 , wherein the step (d) further comprising:

(d1) turning over the top sheet of the N-th bundle of the first row at the first layer; and

(d2) connecting the tail part of the lower portion of the first bundle of the M-th row at the second layer with the top sheet of the N-th bundle of the first row at the first layer on top at the first layer.

14 . The method as claimed in claim 11 , further comprising (g) connecting the lower portion of the first bundle of the m-th row at the second layer with the upper portion of the N-th bundle of the (m+1)th row at the second layer, wherein m=1, 2, . . . M−1.

15 . The method as claimed in claim 8 , wherein arrangement directions respectively extending from the first bundles to the N-th bundles of the M rows at the first layer and the second layer are the same.

16 . A method of manufacturing endless pallet chain sheet material, comprising steps of:

providing a pallet having a longitudinal direction and a lateral direction perpendicular to the longitudinal direction;

providing a chain sheet material;

positioning the chain sheet material on the pallet to include a first row and a second row, wherein:

the first row and the second row are arranged along the lateral direction;

each of the first row and the second row includes a first bundle and a last bundle arranged along the longitudinal direction, wherein the first bundle of the first row and the last bundle of the second row are respectively positioned at an upper layer and a lower right below the upper layer; and

each of the first bundle and the last bundle includes an upper portion and a lower portion; and

connecting the lower portion of the first bundle of the first row with the upper portion of the last bundle of the second row.

17 . The method as claimed in claim 16 , wherein the lower portion of the first bundle of the first row and the upper portion of the last bundle of the first row respectively include a bottom sheet and a top sheet.

18 . A method of manufacturing endless pallet chain sheet material, comprising steps of:

(a) providing a pallet having a longitudinal direction and a lateral direction perpendicular to the longitudinal direction;

(b) providing a chain sheet material;

(c) positioning the chain sheet material on the pallet to include a first row and a second row, wherein:

the first row and the second row are arranged along the lateral direction;

the first row is disposed at a layer the same as or below that disposed at by the second row;

each of the first row and the second row includes N bundles arranged along the longitudinal direction, wherein N≥2 and an arrangement direction extending from the first bundle to an N-th bundle of the first row is the same as that extending from the first bundle to an N-th bundle of the second row; and

each of the N bundles includes an upper portion and a lower portion; and

(d) connecting the lower portion of the first bundle of the first row with the upper portion of the N-th bundle of the second row.