Folded Post Runner Pallet Support
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Solution Overview
Problem
Existing paper-based pallet supports with cylindrical spiral wound cores lack sufficient surface area to withstand impacts from forklift forks during handling, making them prone to damage.
Innovation Solution
A Z-folded or accordion-folded paperboard enclosure with a hollow cylindrical post insert, featuring living hinges that allow it to be folded into a rectilinear shape, providing increased stability and surface area within a hollow elongated paperboard enclosure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a cylindrical spiral wound core is used for the vertical support structure, then the structure is simple to manufacture, but the surface area is insufficient to withstand straight-on impact from forklift forks
Solution Approach 1:
The post is divided into multiple hollow cylindrical segments of equal lengths by making partial cuts around its circumference. These segments are connected by living hinges, creating a segmented structure that can be accordion-folded into a rectilinear shape, thereby increasing the surface area while maintaining manufacturing simplicity
Solution Approach 2:
The post is transformed from a cylindrical shape to a rectilinear shape through accordion-folding along living hinges. This dimensional transformation increases the surface area available to withstand forklift impacts while maintaining the same material footprint, effectively addressing the surface area deficiency of the cylindrical design
2Strength
If a cylindrical shape is used for the support structure, then the manufacturing process is simple, but the structure does not provide sufficient surface area for withstanding impact during rough handling
Solution Approach 1:
The structure incorporates living hinges that allow the post to be dynamically folded from a cylindrical shape into a rectilinear accordion-folded configuration. This dynamic transformation enables the structure to adapt its shape to provide increased impact resistance while maintaining manufacturing simplicity
Solution Approach 2:
The structure combines paperboard material with a folded geometric configuration to create a composite structural form. The accordion-folded rectilinear shape provides enhanced impact resistance compared to a simple cylindrical form, while the paperboard material maintains ease of manufacture
Data Source
AI summary
A folded post support system for supporting a pallet, comprising a hollow elongated enclosure and an insert disposed with the interior of the enclosure. The insert is made from a hollow cylindrical structural post that has been folded in an accordion fashion to form a series of post segments. Each post segment is connected to at least one adjacent post segment along a living hinge.