Foldable Corrugated Pallet Assembly for Lightweight Load Strength
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Solution Overview
Problem
Conventional wooden pallets are costly, heavy, bulky, and cumbersome, requiring substantial storage space and labor-intensive assembly, while recyclable pallets lack structural strength and require intricate fold lines and manual assembly.
Innovation Solution
A foldably constructed pallet using corrugated paperboard blanks secured with adhesive, featuring support columns and rigid members for enhanced rigidity, allowing automated assembly and supporting heavy or uneven loads.
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 requirement is large, and assembly labor is intensive
Solution Approach 1:
The patent changes the material parameter from wood to corrugated paperboard, fundamentally altering the weight-to-strength ratio. The corrugated structure provides sufficient load capacity while reducing weight by approximately 70% compared to traditional wooden pallets, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The patent employs composite construction by combining corrugated paperboard with adhesive bonding systems and structural design elements (such as interlocking features and reinforcement patterns) to create a pallet that achieves wood-like strength characteristics while maintaining the weight advantages of paper-based materials.
2Weight of moving object
If recyclable materials like corrugated paperboard are used, then weight is reduced and environmental impact is lowered, but structural strength is insufficient
Solution Approach 1:
The patent optimizes the corrugated paperboard parameters including flute size, wall thickness, and bonding characteristics to enhance structural strength while maintaining the lightweight and recyclable properties of the material, thereby resolving the strength deficiency of traditional recyclable pallets.
Solution Approach 2:
The patent creates a composite structure by combining corrugated paperboard with adhesive systems and structural design features that work together to achieve enhanced load-bearing capacity, proving that recyclable materials can meet structural requirements when properly engineered.
3Strength
If intricate fold lines and manual assembly are used for recyclable pallets, then structural strength is improved, but assembly time and labor cost increase
Solution Approach 1:
The patent divides the pallet into modular components with standardized connection features that can be assembled through simple, repetitive actions. This segmentation allows for automated assembly while maintaining structural integrity, eliminating the need for complex manual folding and intricate assembly procedures.
Solution Approach 2:
The patent replaces manual mechanical assembly operations with automated adhesive application and bonding systems. The adhesive-based connection system can be applied automatically by machinery, substituting labor-intensive manual folding and assembly while maintaining or enhancing structural strength through consistent bonding quality.
4Strength
If adhesive is applied to substantial portion of interfacing surfaces, then bonding strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces complex mechanical fastening systems with a simplified adhesive bonding process. The adhesive application system, while requiring precision, eliminates the need for multiple mechanical components, drilling operations, and fastener installation, thereby reducing overall manufacturing complexity despite the extended adhesive application area.
Solution Approach 2:
The patent merges multiple manufacturing operations into a single adhesive application and bonding process. By combining positioning, alignment, and fastening functions into one integrated adhesive bonding step, the patent reduces the number of separate manufacturing operations and equipment requirements, thereby simplifying the overall manufacturing system.
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, enabling them to handle heavier and asymmetric loads with improved recyclability and reduced environmental impact.
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.