Cardboard Pallet Container with Triangular Walls
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Solution Overview
Problem
Conventional cardboard pallet containers are prone to bulging, making them unsuitable for economical packing and transport, and often require two people or special tools to deploy from a flat state, which increases handling costs and risks of spillage.
Innovation Solution
A cardboard pallet container with eight side walls, a bottom piece, and leg flaps that can be automatically deployed from a flat position using a series of inside and outside folds, allowing single-person operation without tools, and featuring a design that prevents bulging through strategic score lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional pallet containers are used, then they can hold heavy loads, but they are prone to bulging which prevents economical packing and transport
Solution Approach 1:
The container is divided into eight triangular side walls instead of conventional four rectangular walls. This segmentation distributes the load more evenly across the structure, preventing bulging while maintaining strength. The triangular configuration creates a more stable geometric structure that resists deformation under heavy loads.
Solution Approach 2:
The patent introduces an additional dimensional aspect by using triangular geometry instead of rectangular. The triangular side walls create a three-dimensional pyramidal structure that inherently resists bulging better than conventional rectangular boxes. This dimensional change in the basic geometric unit provides both structural integrity and resistance to deformation.
2Volume of moving object
If conventional pallet containers are deployed from flat state, then they can be stored compactly, but they require two people or special tools to unfold
Solution Approach 1:
The container incorporates dynamic deployment mechanisms where the side walls are connected through hinges or flexible joints that allow automatic unfolding. When the base is expanded, the triangular side walls automatically rise and lock into position through their geometric configuration, eliminating the need for manual assembly or special tools.
Solution Approach 2:
The container structure includes self-deploying features where the geometric configuration of the triangular side walls causes them to automatically unfold and lock into place when the base is expanded. The design uses self-locking mechanisms inherent in the triangular geometry, allowing the container to deploy itself without external assistance or tools.
3Ease of manufacture
If prior art pallet boxes are flipped over for deployment, then they can be assembled, but flimsy boxes may force apart and require re-assembly
Solution Approach 1:
The container is pre-configured with the triangular side walls attached to the base in a folded state during manufacturing. The hinge connections and locking mechanisms are pre-installed, so that when the container is deployed, the side walls automatically unfold and lock into position without requiring the box to be flipped or manually re-assembled.
Solution Approach 2:
The dynamic hinge connections allow the side walls to transition smoothly from the folded storage state to the deployed operational state. The triangular geometry provides inherent stability during this transition, preventing the box from forcing apart and maintaining structural integrity throughout the deployment process.
Data Source
AI summary
A pallet container having eight side walls, a bottom piece, two leg flaps that are used to automatically deploy the container from a flat, collapsed position, and a series of inside folds and outside folds. The pallet container is constructed from one or more blanks made of cardboard. The blanks used to make the pallet container may have different configurations. The pallet container has an open and a closed position and can be converted from one position to the other by a single person without the need of special tools or equipment. A cardboard blank for making the pallet container is also disclosed.