Spiral Corrugated Pallet Runner Segmentation
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Solution Overview
Problem
Existing corrugated pallet designs require complex and expensive equipment to manufacture, leading to slow production rates and high costs, while also struggling to achieve sufficient strength and durability.
Innovation Solution
The development of an elongate pallet runner comprising a plurality of bent panels forming a continuous spiral structure with a nested cross-sectional profile, which is made from corrugated cardboard and can be easily integrated into a pallet formation system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing corrugated pallet designs are used, then recyclable materials can be utilized, but complex and expensive equipment is required leading to slow production rates
Solution Approach 1:
The pallet runner is divided into multiple panels that can be independently formed and then assembled together. Each panel is formed separately using simpler equipment, and then the panels are joined to create the complete runner structure, eliminating the need for complex one-piece forming equipment
Solution Approach 2:
The formation process is extracted into separate stages: first forming individual panels, then assembling them into the complete runner. This separation allows each stage to use simpler, more cost-effective equipment while maintaining overall productivity
2Ease of manufacture
If existing corrugated pallet designs are used, then recyclable materials can be utilized, but manufacturing costs are high
Solution Approach 1:
By segmenting the runner into separate panels, the manufacturing process uses simpler, less expensive equipment for each panel formation step, and the assembly process is straightforward, overall reducing manufacturing costs while maintaining ease of production
Solution Approach 2:
The invention changes the formation parameters by creating panels with specific bend angles and nesting configurations that optimize structural strength while using simpler manufacturing processes, reducing both equipment complexity and manufacturing cost
3Strength
If existing corrugated pallet designs are used, then recyclable materials can be utilized, but sufficient strength and durability are difficult to achieve
Solution Approach 1:
The panels are nested within each other in a compact configuration where inner panels are positioned inside the hollow space created by outer panels. This nesting arrangement maximizes the use of material while maintaining a compact form factor, achieving sufficient strength without excessive structural complexity
Solution Approach 2:
The pallet runner uses composite construction combining corrugated cardboard panels with adhesive bonding, creating a multi-layer composite structure that achieves high strength and durability while keeping the overall design relatively simple
4Strength
If wooden pallets are used, then strong and durable, but heavy weight adds to transportation cost
Solution Approach 1:
The invention changes the material parameter from heavy wood to lightweight corrugated cardboard, and adjusts the structural parameters (panel thickness, nesting configuration, adhesive bonding) to compensate for the lighter material, achieving sufficient strength while significantly reducing weight
Solution Approach 2:
The pallet uses composite construction with multiple corrugated cardboard panels bonded together, creating a lightweight yet strong structure that replaces heavy wood while maintaining durability and load-bearing capacity
Data Source
AI summary
The present disclosure generally relates to elongate pallet runners, pallets comprising a plurality of elongate pallet runners and methods, systems and apparatuses for forming said elongate pallet runners and pallets. The elongate pallet runners each comprise a plurality of panels, where each panel is bent relative to an adjacent panel to form a continuous spiral structure having a cross-sectional profile that is nested. Each panel has a planar surface that abuts against a planar surface of another panel.