Corrugated Pallet Design Using Two Flat Blanks for High Torsional Stiffness
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing corrugated paperboard pallets face issues of low strength and stiffness, high material costs, and challenges in high-volume production and distribution due to complex assembly requirements and material usage.
Innovation Solution
A corrugated paperboard pallet design utilizing only two flat blanks, which are folded to create two parallel ribs, three horizontal panels, two vertical sidewalls, and two horizontal flaps, allowing for 100% machine assembly with a low-cost machine, reducing material usage and enabling high-volume production while maintaining strength and stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional corrugated paperboard pallets are designed with multiple ribs and complex structures to increase strength and stiffness, then load-bearing capability is improved, but material costs and assembly complexity increase
Solution Approach 1:
The pallet is divided into two separate flat blanks (top and bottom) that are folded and assembled together. Each blank is segmented into functional regions (ribs, panels, flaps, sidewalls) that are formed through folding rather than complex construction, simplifying manufacturing while maintaining structural integrity
Solution Approach 2:
Instead of building up complex 3D structures from multiple components, the invention inverts the approach by starting with flat 2D blanks and forming the 3D structure through folding. This reversal simplifies the manufacturing process and reduces assembly complexity while achieving the required strength through the folded geometry
2Strength
If more corrugated paperboard material is used to increase pallet strength and stiffness, then structural performance is improved, but material costs increase
Solution Approach 1:
The invention utilizes the inherent flexibility and strength of corrugated paperboard thin sheets, folding them into rigid 3D structures. The corrugated geometry itself provides the structural reinforcement, eliminating the need for excessive material while achieving the required strength and stiffness through smart structural design
Solution Approach 2:
The invention changes the geometric parameters of the corrugated paperboard through folding, transforming flat 2D blanks into 3D structures with enhanced mechanical properties. The folding process creates rib structures, vertical sidewalls, and horizontal flaps that significantly improve strength and stiffness without increasing material quantity
3Strength
If complex assembly processes are used to achieve high strength and stiffness, then structural performance is improved, but production volume and distribution efficiency decrease
Solution Approach 1:
The flat blanks are pre-designed with fold lines and geometric features that enable self-assembly into the final pallet structure. The preliminary design of the flat blanks includes all necessary geometric information for forming the ribs, panels, and flaps, allowing rapid assembly without complex manufacturing processes and enabling high-volume production
4Adaptability or versatility
If traditional pallet designs are used to meet diverse shipping requirements, then versatility is maintained, but material costs and weight increase
Solution Approach 1:
The pallet design provides universal functionality by creating a standardized structure that can handle various loading conditions and shipping requirements. The two-blank design with folded ribs and flaps creates a versatile pallet that meets 70% of shipping market needs, reducing the variety of different pallet types required while maintaining adaptability through the structural design
Data Source
AI summary
A corrugated pallet produced from two flat blanks is provided. The pallet may include a pallet top, a pallet bottom, and a plurality of corner straps locking the pallet top to the pallet bottom. Each of the pallet top and the pallet bottom may include folded portions, the folded portions of the pallet top interlocking with the folded portions of the pallet bottom when the pallet top and the pallet bottom are assembled to each other in nested relation. The pallet top may define a top surface of the pallet. The pallet bottom may define a bottom surface of the pallet. The corner straps may lock into one or both of the pallet top and the pallet bottom from the top or bottom surfaces of the pallet.