Folded Corrugated Pallet Structural Design

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Solution Overview

Problem

Conventional pallets, such as wood and molded polymer pallets, are heavy, prone to breakage, and not recyclable, while corrugated cardboard pallets lack sufficient weight capacity and durability for repeated use.

Innovation Solution

A folded corrugated pallet design utilizing a single sheet of corrugated cardboard with scored lines to create legs, base walls, and wings, providing increased strength and weight capacity, and allowing for recyclability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If wood or molded polymer pallets are used, then weight capacity and durability are improved, but weight increases and recyclability deteriorates

Engineering Contradiction:

Improveweight capacityVSAvoidpallet weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent changes the material parameter from traditional wood or polymer to corrugated cardboard, fundamentally altering the weight-to-strength ratio. The corrugated structure provides sufficient weight capacity while dramatically reducing overall pallet weight, enabling the pallet to be manually handled and reducing fuel consumption in material handling operations.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite construction by bonding multiple corrugated cardboard layers together to form a multi-layer panel structure. This composite approach allows the pallet to achieve the necessary strength and weight capacity for industrial use while maintaining the lightweight and recyclable properties of corrugated cardboard.

Inventive Principle:

Principle #40Composite materials

2Strength

If wood or molded polymer pallets are used, then weight capacity is improved, but recyclability deteriorates

Engineering Contradiction:

Improveweight capacityVSAvoidrecyclability

Core Design Contradiction:

StrengthVSLoss of substance

Solution Approach 1:

The patent changes the material composition parameter to use entirely corrugated cardboard, which is inherently recyclable. This material substitution maintains adequate weight capacity through proper structural design while ensuring the pallet can be recycled at end-of-life, eliminating the waste associated with disposing of wood or polymer pallets.

Inventive Principle:

Principle #35Parameter changes

3Weight of moving object

If corrugated cardboard pallets are used, then weight is reduced and recyclability is improved, but weight capacity and durability deteriorate

Engineering Contradiction:

Improvepallet weightVSAvoidweight capacity

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent uses composite construction by bonding multiple corrugated cardboard layers together to create a multi-layer panel. This composite structure significantly increases the weight capacity and durability of the pallet compared to single-layer designs, while maintaining the lightweight and recyclable advantages of corrugated cardboard.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent divides the pallet structure into multiple segments including side walls, end walls, and a top panel, all constructed from corrugated cardboard. This segmentation allows each component to be optimized for its specific function while collectively providing sufficient weight capacity and structural integrity for repeated use in material handling operations.

Inventive Principle:

Principle #1Segmentation

4Ease of manufacture

If corrugated cardboard pallets are used, then cost is reduced, but durability and reusability deteriorate

Engineering Contradiction:

Improvemanufacturing costVSAvoidpallet lifespan

Core Design Contradiction:

Ease of manufactureVSDuration of action of stationary object

Solution Approach 1:

The patent employs composite construction with multiple bonded corrugated cardboard layers to create a durable pallet structure. This multi-layer composite design significantly improves durability and reusability compared to single-layer corrugated pallets, allowing the pallet to withstand repeated use in industrial material handling while maintaining low manufacturing costs.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS10351297B2Light weight folded corrugated pallet

Publication Date: 2019.07.16 PREFERRED PACKAGING SOLUTIONS INC

AI summary

The invention generally relates to devices used for material handling, such as specifically, pallets and skids. More specifically, the present invention is directed toward a folded corrugated pallet including a body defined by a single sheet of corrugated cardboard. The sheet includes a plurality of scored lines extending parallel with respect to each other. The sheet is folded along the scored lines to define a plurality of legs extending in the direction of the scored lines and at least one base wall extending between each of the legs. A pair of wings extends parallel to the scored lines and away from each other when folded parallel to the base wall. A planar top panel is disposed on top of the wings and the base wall. The planar top panel and the wings cooperate to define terminal edges of the pallet that extend in cantilevered fashion adjacent one of the legs.