Structural Cardboard Runner With M-Shaped Cross Section
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Solution Overview
Problem
Traditional wood pallets are expensive and difficult to dispose of, while cardboard pallets lack durability and strength, especially when subjected to horizontal and vertical abuse from fork truck tines and heavy packages.
Innovation Solution
A structural cardboard runner with an M-shaped cross section, reinforced with adhesive bonding and notches for fork lift tines, forming a tubular shape that provides rigidity and support, and a pallet design incorporating these runners with a deck and additional cross beams for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional wood pallets are used, then durability and strength are improved, but cost and disposal difficulty increase
Solution Approach 1:
The patent changes the physical parameters of cardboard by transforming it from a flat sheet into a three-dimensional tubular structure with an M-shaped cross section. This geometric transformation increases the moment of inertia and section modulus, thereby significantly improving the bending strength and load-bearing capacity of the cardboard runner while maintaining the use of inexpensive cardboard material.
Solution Approach 2:
The patent creates a composite structure by combining multiple layers of cardboard in a specific configuration. The M-shaped cross section with its flanges and web forms a multi-layered composite structure that leverages the strength of each layer while distributing loads effectively, achieving wood-like durability at a fraction of the cost.
2Ease of manufacture
If simple cardboard runners are used, then cost is reduced, but ability to withstand horizontal and vertical abuse deteriorates
Solution Approach 1:
The patent employs curved and folded geometries in the M-shaped cross section, including the flanges extending from the web and the triangular reinforcement portions. These curved and folded structures increase the section modulus and distribute stresses more effectively than straight, simple rectangular sections, enabling the runner to withstand horizontal abuse from fork truck tines and vertical abuse from heavy packages.
Solution Approach 2:
The patent incorporates notches cut into the runner at specific locations before assembly. These notches are positioned to receive fork truck tines, allowing the tines to engage and disengage without applying excessive lateral forces that could damage the runner. This preliminary design feature prevents damage before it occurs during handling operations.
3Ease of manufacture
If cardboard pallets are used, then cost and disposal efficiency are improved, but strength and durability deteriorate
Solution Approach 1:
The patent transforms the two-dimensional flat cardboard sheet into a three-dimensional tubular structure with an M-shaped cross section. This dimensional transformation creates a structure with higher moment of inertia and section modulus, significantly improving bending strength and load-bearing capacity. The tubular geometry provides structural rigidity that allows the cardboard runner to support heavy loads while maintaining the cost and disposal advantages of using cardboard.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a durable and strong pallet system capable of withstanding significant vertical and horizontal loads, reducing material costs and improving disposal efficiency by using recyclable materials.
Implementation Method 1
Adhesive bonds the third portion to the first and second portions
Data Source
AI summary
A runner for pallets includes a cardboard sheet folded to include a first portion forming an M shape, a second portion folded across the M shape to form two closed triangles, and a third portion folded around the M shape including sections along and adjacent a first outer leg of the M shape and across the M shape and along and adjacent a second outer leg of the M shape. Adhesive bonds the third portion to the first and second portions. The arrangement forms a beam of sufficient structural rigidity to support the vertical and horizontal “abuse” often received by pallets. Notches for fork lift tines are cut into the length for matching a typical location of the fork lift tines. A pallet includes a deck such as cardboard or other material, and three runners attached to a bottom of the deck.