Corrugated Pallet Deck Reinforcing Plates Impact Absorption
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Solution Overview
Problem
Corrugated fiberboard pallets are susceptible to damage from impacts and stresses, such as those caused by forklifts, leading to tearing and breaking of the adhesive bonds between the deck and stringers, which increases waste and environmental footprint, and existing reinforcement methods are either heavy or expensive.
Innovation Solution
Incorporating reinforcing plates between corrugate sheets in the upper and lower decks of the pallet, aligned with the edges to absorb forces and mitigate damage, while maintaining a lightweight and cost-effective design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hardboard or stronger sheet is integrated into the corrugated fiberboard deck to strengthen it, then the deck strength is improved, but the weight and cost increase
Solution Approach 1:
The patent applies local quality by positioning reinforcing plates only at specific high-stress locations (edges and corners) rather than using a uniform hardboard sheet across the entire deck. This localized reinforcement provides necessary strength at critical points while maintaining the lightweight corrugated fiberboard construction in non-critical areas, thus improving deck strength without proportionally increasing weight.
Solution Approach 2:
The patent uses composite materials by combining corrugated fiberboard with strategically placed reinforcing plates made of different materials (such as plastic, metal, or composite materials). This composite approach creates a hybrid structure that leverages the lightweight properties of corrugated fiberboard while incorporating the strength of reinforcing plates only where needed, resolving the contradiction between strength and weight.
2Strength
If hardboard or stronger sheet is integrated into the corrugated fiberboard deck to strengthen it, then the deck strength is improved, but the cost increases
Solution Approach 1:
The patent reduces cost by applying local quality - using reinforcing plates only at critical high-stress locations rather than covering the entire deck with expensive hardboard. This selective reinforcement approach maintains necessary strength while significantly reducing material costs compared to full-coverage hardboard solutions.
Solution Approach 2:
The patent applies partial action by using minimal reinforcement only where absolutely necessary (edges and corners subject to forklift impact) rather than providing uniform reinforcement across the entire deck. This partial reinforcement strategy achieves adequate strength at lower cost by avoiding excessive material usage in non-critical areas.
3Object-affected harmful factors
If the pallet is made from corrugated fiberboard to improve sustainability and reduce cost, then environmental footprint is reduced, but durability against impact damage deteriorates
Solution Approach 1:
The patent applies beforehand cushioning by incorporating reinforcing plates at edges and corners before impact occurs. These reinforcing elements are pre-positioned to absorb and distribute the energy of anticipated forklift impacts, preventing the kind of damage that would otherwise occur to plain corrugated fiberboard pallets, thus improving durability while maintaining sustainability.
Solution Approach 2:
The patent uses an intermediary (the reinforcing plate) between the forklift tine and the corrugated fiberboard deck. The reinforcing plate acts as a mediator that absorbs and distributes impact forces, protecting the underlying corrugated fiberboard from direct damage. This allows the pallet to maintain its sustainable corrugated fiberboard construction while gaining the durability needed to withstand harsh warehouse environments.
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 effectively absorbs impact forces from forklifts and pallet jacks, reducing damage to the pallet and maintaining recyclability, thereby enhancing durability and sustainability without increasing weight or cost.
Implementation Method 1
Each reinforcing plate defines an impact edge aligned with an edge of the upper deck to absorb a force from a tine of a forklift
Data Source
AI summary
A shipping pallet apparatus (10) comprises an upper deck (12) comprising a plurality of corrugate sheets bonded in lamination to one another, a plurality of stringers (18) or blocks (19) adhesively secured to a lower surface of the upper deck (12), and a plurality of reinforcing plates (16) secured between adjacent corrugate sheets of the plurality of corrugate sheets, each reinforcing plate (16) of the plurality of reinforcing plates positioned between two stringers (18) or two blocks (19) of the plurality of stringers or blocks to define a medial gap (32) and a lateral gap (34), and each reinforcing plate (16) defining an impact edge aligned with an edge of the upper deck (12) to absorb a force from a tine.