Integrated Pallet Box with Compressed Fiberboard Pegs
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Solution Overview
Problem
Traditional pallet box systems are inefficient due to the need for separate pallets and containers, leading to increased labor costs, storage space requirements, and safety hazards from loose contents and pallets during movement and storage.
Innovation Solution
A pallet box that integrates a storage container and pallet into a single unit with fully sealing top and bottom planes, using pressure-sensitive adhesive strips and pegs made of compressed fiberboard for secure closure and forklift compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate pallets and containers are used, then contents can be stored and transported, but labor costs increase and storage space is consumed
Solution Approach 1:
The patent combines the container and pallet into a single integrated unit. The container's bottom flaps are extended to form a pallet base with fork slots, eliminating the need for separate pallets. This merger reduces the number of components from two (container + pallet) to one (integrated unit), directly addressing the technical contradiction by reducing system complexity while maintaining both storage and transport functions.
Solution Approach 2:
The integrated bottom flaps serve multiple functions: they form the container base for storing contents, create a pallet structure for forklift insertion and transport, and provide structural support for the entire unit. This multi-functionality allows a single component to replace what previously required separate pallet and container elements, improving labor cost efficiency by eliminating the need to handle and store separate pallets.
2Reliability
If traditional box flaps are used, then the box can be assembled, but items may fall out due to incomplete sealing
Solution Approach 1:
The bottom of the container is divided into multiple flaps (front, rear, and side flaps) that can be independently folded and sealed. This segmentation allows each flap to be separately managed and secured, ensuring complete coverage of the bottom opening while maintaining assembly simplicity through standardized folding and taping procedures for each individual flap.
Solution Approach 2:
The bottom flaps are pre-positioned and folded into place before the container is fully assembled and loaded with contents. This preliminary action ensures that the bottom is completely sealed and secure before items are placed inside, preventing any risk of items falling out during subsequent handling or transport operations.
3Area of stationary object
If pallets are stored separately, then they can be reused, but storage space is occupied and safety hazards exist
Solution Approach 1:
By integrating the pallet structure directly into the container bottom, the invention eliminates the need for separate pallet storage. The pallet base is permanently attached to the container, so when the container is stored, the pallet is automatically stored with it. This merger frees up dedicated pallet storage space and eliminates safety hazards associated with storing loose pallets that could cause trips or falls.
Solution Approach 2:
The invention extracts the pallet function from the separate pallet component and embeds it directly into the container structure. By taking out the pallet as a distinct element and integrating its essential features (flat base, fork slots) into the container's bottom flaps, the design eliminates the need for separate pallet storage while maintaining all necessary pallet functions for forklift insertion and transport.
4Ease of operation
If loose contents are transported on separate pallets, then items can be moved, but contents may shift and fall during movement
Solution Approach 1:
The integration of the pallet base with the container creates a unified structure where contents are stored within the container walls and secured on the integrated pallet base. This merger ensures that contents cannot shift or fall between the container and pallet interface, as there is no such interface— they are part of the same continuous structure. The result maintains transport ease through forklift insertion while ensuring content stability during movement.
Data Source
AI summary
A system is provided comprising a box with four bottom flaps, at least four durable pegs projecting from exterior surfaces of two opposing bottom flaps, the pegs positioned to function as a built-in pallet structure for the box, adhesive strips on interior surfaces of the two opposing bottom flaps to promote closure of the bottom flaps, four top flaps, interior surfaces of two opposing top flaps containing protected adhesive strips to promote closure of the top flaps, and wax paper covering the adhesive strips prior to use of the strips. The pegs are constructed from the same material as the box. Material comprising the pegs is denser than material comprising the box. The denser concentration of the peg material enables the pegs to sustain weight of the box and contained items. The pegs are positioned on the opposing bottom flaps.