Pallet-Free Bulk Bin Container with Integrated Runners
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Solution Overview
Problem
Conventional corrugated paperboard containers require separate wooden pallets for handling, which are heavy, expensive, and difficult to transport and recycle, and existing integrated container and pallet constructions face challenges in shipping in a knocked-down state and assembling at user destinations.
Innovation Solution
A corrugated paperboard pallet-free bulk bin container with integrated corrugated pallet and optional lid, designed to fold easily from a knocked-down to an open position, eliminating the need for separate pallets and allowing for efficient stacking, storage, and international shipping without lumber treatment codes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate wooden pallets are used with conventional containers, then handling and transport capability is improved, but weight, cost, and difficulty of transport and recycling worsen
Solution Approach 1:
The patent integrates the pallet structure directly into the container by forming outboard runners along the outer side edges of the container and openings inboard of the runners for receiving forklift tines. This merging eliminates the need for separate wooden pallets, reducing weight and cost while maintaining handling capability.
Solution Approach 2:
The container structure serves multiple functions: it provides cargo containment and simultaneously integrates pallet-like handling features through the outboard runners and tine-receiving openings. This multi-functionality allows the container to be both a cargo holder and a pallet substitute.
2Ease of operation
If containers are stacked on separate pallets, then handling is improved, but container displacement and damage risk worsen
Solution Approach 1:
By merging the pallet structure with the container, the outboard runners and tine-receiving openings become integral parts of the container. This integration ensures that containers remain securely positioned during handling operations, eliminating the displacement and damage risks associated with separate pallets.
3Ease of operation
If integrated container and pallet constructions are used, then handling capability is improved, but ability to ship in knocked-down state and assemble at destination worsens
Solution Approach 1:
The integrated structure is designed as a foldable construction that can be segmented into a knocked-down flat configuration for shipping. The outboard runners and container walls can be folded or collapsed together, allowing the integrated design to be transported efficiently and then assembled at the destination.
4Strength
If wooden pallets are used, then handling strength is improved, but recyclability and international shipping compliance worsen
Solution Approach 1:
The patent replaces expensive, treatment-regulated wooden pallets with a corrugated paperboard construction that is inherently compliant with international shipping regulations. The paperboard material requires no lumber treatment and can be easily recycled or disposed of after use.
Solution Approach 2:
The invention uses corrugated paperboard as a composite material to create a pallet-like structure that combines strength with environmental compliance. The layered paperboard construction provides adequate handling strength while eliminating the need for wood treatment certifications.
Data Source
Figure 1
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AI summary
A pallet-free bulk bin container (10) comprises an open-ended bulk bin (12) having a frame base (35) at one end. A pair of channel inserts (14a, 14b) is configured to be engaged with the frame base to form pallet runners. A pair of center-filler supports (16a, 16b) is configured to enclose one end of the open-ended bulk bin. The bulk bin container may be shipped in a collapsed or knocked-down state and easily assembled into a larger container for use and being disassembled for re-use.