Cardboard Pallet Beam Assembly for Heavy-Load Strength
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Solution Overview
Problem
Existing pallet systems are inefficient in terms of space utilization and structural integrity, particularly when handling heavy loads, and there is a need for a more sustainable and cost-effective alternative to traditional materials.
Innovation Solution
A cardboard-based pallet system is designed with specific bend lines, apertures, and notches that allow for efficient bending and assembly into longitudinal beam members, incorporating forklift access cutouts, using corrugated cardboard that can be sourced from recycled or biodegradable materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional materials are used for pallet systems, then structural strength is maintained, but material costs and environmental impact increase
Solution Approach 1:
The patent changes the material parameters by using corrugated cardboard with specific flute configurations (e.g., double-wall or triple-wall structures) and controlled fiber density to achieve required strength levels while maintaining biodegradability and recyclability, thus reducing environmental impact compared to traditional plastic or wooden pallets
Solution Approach 2:
The patent employs composite material construction by layering multiple corrugated cardboard sheets with alternating orientations and bonding them through adhesive or mechanical interlocking, creating a composite structure that achieves structural strength comparable to traditional materials while preserving the environmental benefits of cardboard
2Loss of substance
If cardboard material is used for pallet systems, then material costs and environmental impact are reduced, but structural strength and load-bearing capacity decrease
Solution Approach 1:
The patent segments the cardboard structure into multiple functional layers including outer flat sheets for load distribution, inner corrugated layers for structural rigidity, and reinforcement zones at critical stress points, allowing each segment to optimize its contribution to overall strength while maintaining material efficiency
Solution Approach 2:
The patent incorporates curved and angled geometries in the cardboard beam designs, including arched top and bottom members that distribute loads more effectively, and angled support members that optimize force transmission, thereby enhancing load-bearing capacity without increasing material usage
3Manufacturing precision
If complex bend lines and aperture patterns are implemented, then assembly precision and structural integrity are improved, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates pre-creased bend lines and pre-punched aperture patterns during the cardboard sheet manufacturing process, so that when the sheets are assembled into pallet components, the bending and alignment operations require minimal additional processing, thereby achieving high assembly precision without proportionally increasing manufacturing complexity
Solution Approach 2:
The patent applies different aperture patterns and bend line configurations to specific local regions of the cardboard sheets based on functional requirements - for example, denser aperture patterns in connection zones for enhanced joining, and specific bend line radii at stress concentration points - rather than uniform patterns throughout, optimizing performance while controlling overall complexity
Data Source
AI summary
A pallet system includes first bent cardboard sheets with sheet portions, first apertures, second apertures, and with bends that place the sheet portions in juxtaposition thereby forming first beam members with engagement notches and forklift blade access cutouts. Second beam members are similarly formed to couple with the first beam members resulting in a base assembly for a pallet system. Other aspects are described in the claims, drawings, and text forming a part of the present disclosure.