Stack-Top Dunnage with Folded Ledges for Pile Stability

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Solution Overview

Problem

The existing use of wood sheets as stack-top dunnage for material stacks is costly, cumbersome, and heavy, and does not effectively prevent the opening or falling of individual piles during shipping.

Innovation Solution

A stack-top dunnage system comprising folded sheet materials with ledges that are spaced apart to receive tie bands, providing structural support and bridging gaps between piles, made from cellulose pulp sheet materials like cardboard, which can be produced with slits and adhesives for enhanced folding and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If wood sheets are used as stack-top dunnage, then structural support and pressure distribution are improved, but cost, weight, and handling difficulty increase

Engineering Contradiction:

Improvestructural supportVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent changes the material parameter from wood to corrugated cardboard, which has different physical properties but can achieve similar structural support functions when properly configured with ledges and folds

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The dunnage is segmented into multiple functional zones: central ledges for band engagement, side ledges for pile containment, and folded sections for adaptability, allowing each segment to perform its specific function efficiently

Inventive Principle:

Principle #1Segmentation

2Strength

If wood sheets are used as stack-top dunnage, then structural support is improved, but cost and handling difficulty increase

Engineering Contradiction:

Improvestructural supportVSAvoidhandling

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The dunnage incorporates dynamic elements through accordion folds and collapsible ledges that can adapt to different stack configurations, making it easier to handle and adjust compared to rigid wood sheets

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent uses flexible corrugated cardboard with fold lines that allow the dunnage to conform to various stack shapes and sizes, improving ease of operation while maintaining structural support

Inventive Principle:

Principle #30Flexible shells and thin films

3Adaptability or versatility

If individual piles are stacked without linking, then stacking flexibility is improved, but pile stability deteriorates as piles can open or fall during shipping

Engineering Contradiction:

Improvestacking flexibilityVSAvoidpile stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The dunnage acts as an intermediary linking element between individual piles, with side ledges that extend over pile gaps to prevent them from opening or falling during shipping while maintaining stacking flexibility

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent merges multiple functions into a single dunnage structure: the central ledge combines band engagement with pile linking, while side ledges simultaneously contain multiple piles and provide structural rigidity

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS8221869B2Stack-top dunnage

Publication Date: 2012.07.17 CASCADES CANADA INC

AI summary

The stack-top dunnage can have a sheet having two opposite end sections and a center section therebetween; each end section being successively folded thus forming a thicker ledge portion. The stack-top protector can be placed on top of a stack and the ledges thence receive tie bands that tie the stack to a pallet for shipping.