Hot Melt Adhesive Stacked Pallet Stabilization
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Solution Overview
Problem
Existing pallet stabilization methods require excessive packaging materials, including inter-layers and pallet wraps, which complicate storage and transportation while being inefficient in securing secondary packages.
Innovation Solution
A stacked pallet design utilizing hot melt adhesive sandwiched between layers of secondary packages, composed of ethylene copolymers, styrene block copolymers, or olefin-based polymers, with limited plasticizer content, to stabilize the pallet without inter-layers and pallet wraps, allowing for easy removal of secondary packages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional inter-layers and pallet wraps are used to stabilize the stacked pallet, then transportation stability is improved, but packaging material quantity and device complexity increase
Solution Approach 1:
The patent extracts and eliminates the traditional inter-layers and pallet wraps from the packaging system, replacing them with hot melt adhesive applied directly to the secondary packages. This removal of unnecessary components reduces packaging material quantity while maintaining stabilization function through the adhesive bonding layers together.
Solution Approach 2:
The patent merges the stabilization function previously performed by separate inter-layers and pallet wraps into a single hot melt adhesive system. The adhesive combines bonding and stabilization functions in one material, reducing overall packaging material quantity while achieving the same transportation stability.
2Reliability
If traditional inter-layers and pallet wraps are used to stabilize the stacked pallet, then transportation stability is improved, but device complexity increases
Solution Approach 1:
The patent removes the complex multi-component system of inter-layers and pallet wraps, replacing it with a simple hot melt adhesive application system. This extraction simplifies the packaging structure while maintaining transportation stability through direct adhesive bonding between layers.
Solution Approach 2:
The patent combines multiple packaging components (inter-layers and pallet wraps) into a single hot melt adhesive system, reducing device complexity. The adhesive performs the stabilization function that previously required multiple separate components, simplifying the overall packaging structure.
3Quantity of substance
If hot melt adhesive is used to stabilize the pallet without inter-layers and pallet wraps, then packaging material quantity is reduced, but adhesive application precision must be controlled
Solution Approach 1:
The patent specifies precise parameter ranges for the hot melt adhesive including viscosity (500-5000 cP at application temperature), plasticizer content (5-20% by weight), and application temperature (100-150°C). These parameter controls ensure consistent adhesive performance and reliable bonding without requiring complex application equipment, achieving both material reduction and precision control.
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 solution achieves a stable pallet with reduced packaging materials, enhancing transportation stability and ease of secondary package removal at the point of use.
Implementation Method 1
a hot melt adhesive sandwiched between the layers of secondary packages thereby adhering the layers to each other
Implementation Method 2
encasing the primary packages in a plastic film shrunk by heat to form a plurality of individual secondary packages
Data Source
AI summary
The inventors have discovered that certain hot melt adhesives can be used to form a stable stacked pallet that can limit the need for additional packaging materials e.g. inter-layer and pallet wrap.