Foldable Corrugated Pallet Assembly for Higher Load Capacity
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Solution Overview
Problem
Conventional wooden pallets are costly, heavy, bulky, and require substantial storage space, while recyclable pallets made of materials like corrugated paperboard lack structural strength and require labor-intensive assembly.
Innovation Solution
A foldably constructed pallet using corrugated paperboard blanks secured with adhesive, featuring support columns and rigid members to enhance rigidity, allowing automated assembly and improved load capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional wooden pallets are used, then load capacity and structural strength are sufficient, but weight is high, storage space is substantial, and cost is high
Solution Approach 1:
The patent changes the material parameter from wood to corrugated paperboard, fundamentally altering the density and weight characteristics while maintaining structural functionality through optimized blank geometry and folding patterns
Solution Approach 2:
The invention uses corrugated paperboard, which is itself a composite material consisting of layered paper structures with fluted intermediate layers, providing strength-to-weight ratio improvements over solid wood
2Weight of moving object
If recyclable corrugated paperboard pallets are used, then weight is reduced and storage space is minimized, but structural strength is insufficient
Solution Approach 1:
The pallet blank is divided into multiple functional zones including support columns, stringers, deck boards, and reinforcement sections, each optimized for its specific structural role to maximize strength from the lightweight material
Solution Approach 2:
The flat two-dimensional blank is transformed into a three-dimensional structured pallet through folding, creating vertical support columns and spatial configurations that provide structural strength absent in the flat state
3Ease of manufacture
If recyclable pallets with intricate fold lines and tabs are used, then material recyclability is achieved, but assembly complexity increases and labor intensity rises
Solution Approach 1:
The patent removes complex tab-and-slot interlocking mechanisms from the design, extracting only the essential folding lines needed to transform the blank into the finished pallet, thereby simplifying assembly while maintaining recyclability
Solution Approach 2:
The pallet blank is designed with self-aligning fold lines and inherent geometric features that guide the folding process, allowing the structure to self-assemble into its final configuration without requiring complex external fixtures or manual alignment procedures
4Productivity
If conventional wooden pallets are transported empty, then reuse is enabled, but shipping costs increase due to substantial storage space requirements
Solution Approach 1:
The pallet transitions from a rigid fixed-volume wooden structure to a dynamic collapsible structure made of flexible corrugated paperboard that can be folded flat for storage and transported in a compact state, then expanded at the destination for use
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 pallets provide increased structural strength, reduced weight, lower shipping costs, and easier assembly, while being recyclable and suitable for transporting heavier and uneven loads.
Implementation Method 1
the top blank and the bottom blank are secured together, such as through adhesive applied to a substantial portion of one or more interfacing surfaces between the two blanks
Data Source
AI summary
A method of assembling a pallet using a machine includes folding a first portion of a pallet support column to define a vertical support structure. The method further includes folding a second portion of the pallet support column to engage the vertical support structure. The method further includes gluing at least a portion of the second portion to the first portion. The method further includes coupling the pallet support column to at least one of a bottom member or a top member of the pallet.