Corrugated Paperboard Pallet Monolithic Leg Integration
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Solution Overview
Problem
Existing paper-based pallets are prone to leg breakage during transportation due to independent leg attachment, leading to instability and damage, and their production processes are often complex and environmentally unfriendly.
Innovation Solution
A pallet design featuring a corrugated paperboard structure with folding rectangular base plates, lifting holes, and bracing spaces, where the fixing surface is attached to a bracing plate, and completely filled beams are integrated with cylinders in the bracing spaces of the supporting legs, enhancing stability and load-carrying capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If legs are attached to the loading surface as independent units, then the production process is simpler, but the legs break during transport when higher force is exerted by truck forks
Solution Approach 1:
The patent merges the legs with the loading surface by creating a monolithic structure where legs are integrally formed with the base plate through folding operations. This eliminates separate attachment processes while ensuring the legs cannot detach during transport, resolving the contradiction between manufacturing simplicity and transport reliability.
Solution Approach 2:
The loading surface is segmented into multiple functional zones including bracing spaces between legs that are filled with additional paperboard material. This segmentation allows the structure to be assembled from flat components while creating an integrated three-dimensional form that provides both manufacturing ease and structural reliability.
2Object-affected harmful factors
If traditional paper-based pallets are used, then the production is environmentally friendly, but the load-carrying capacity and stability are insufficient
Solution Approach 1:
The patent uses composite construction by layering and folding multiple sheets of corrugated paperboard to create a structure with enhanced mechanical properties. The combination of multiple paperboard layers with integrated bracing elements provides sufficient load-carrying capacity while maintaining environmental friendliness through reusable paper-based materials.
Solution Approach 2:
The patent applies local reinforcement by filling the bracing spaces between legs with additional paperboard material, creating localized areas of increased strength where mechanical stresses are highest. This allows the pallet to achieve high load-carrying capacity in critical areas while maintaining overall environmental sustainability.
3Device complexity
If the pallet structure is simplified with independent legs, then the manufacturing is easier, but the pallet becomes unstable and prone to damage
Solution Approach 1:
The patent combines the legs, loading surface, and bracing elements into a single integrated structure formed by folding operations on paperboard sheets. This merging eliminates the need for separate attachment operations while ensuring structural stability, as all components are monolithically connected and cannot become detached during use.
Data Source
AI summary
The pallet includes two fixing surfaces produced from rectangular base plate with the help of scoring and made by folding and having two lifting holes, and supporting cover containing legs having intrinsic lifting holes and bracing space, the fixing surface of the supporting cover is fixed to bracing plate, which is fixed to the lower surface of the loading surface of the pallet, and to the bottom of the bracing plate the middle supporting cover is fixed, which is formed by folding from rectangular middle base plate created with scorings and two lifting holes, containing the supporting legs which include the two fixing surfaces, lifting holes and bracing space, along the entire length of its two fixing surfaces and the bracing space of the supporting legs, in its upper part completely filled beams are fixed, and cylinders are fixed in a space filleting manner below the completely filled beams in the bracing space of the supporting legs.