Tray-Equipped Pallet Separation Structure for Recyclable Packaging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional tray-equipped pallets, used for packing heavyweight products, require separation of materials for enhanced recyclability but lack easy disassembly methods.
Innovation Solution
A tray-equipped pallet design that includes a pallet made of wood and a tray made of corrugated cardboard, secured together with a support plate, featuring engagement holes, zipper portions, and breakable connections for easy separation into distinct components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tray and pallet are made of different materials (corrugated cardboard and wood/metal), then recyclability is enhanced, but separation of the components becomes difficult
Solution Approach 1:
The tray bottom surface is divided into multiple separable portions through zipper portions that allow the tray to be divided into first and second bottom surface portions. These portions can be independently removed from the pallet, facilitating material separation for recycling purposes.
Solution Approach 2:
Zipper portions and breakable connection portions are pre-formed in the tray structure during manufacturing. These pre-prepared separation features enable easy disassembly without requiring additional tools or complex operations at the time of recycling.
2Strength
If the tray is securely attached to the pallet for transport stability, then structural integrity is maintained, but disassembly requires tools and becomes complex
Solution Approach 1:
The connection between tray and pallet transitions from a fixed secure state during transport to an easily separable state during disassembly. Zipper portions and breakable connection portions allow the structure to dynamically change from connected to separated without requiring tools.
Solution Approach 2:
The zipper portions and breakable connection portions are designed as sacrificial elements that can be easily destroyed or separated. These components are intended to be discarded or separated rather than reused, enabling simple disassembly after the packaging has served its purpose.
3Strength
If the engagement hole is made strong to secure the connection portion, then the tray remains firmly attached, but the engagement hole becomes difficult to break for separation
Solution Approach 1:
The engagement hole has different structural properties at different locations. The main body of the engagement hole provides strong attachment, while specific portions adjacent to the zipper portions are designed to be breakable. This local differentiation allows both strong securing and easy separation.
Solution Approach 2:
The engagement hole is divided into a secure main portion and breakable portions adjacent to the zipper portions. This segmentation allows the engagement hole to simultaneously provide strong attachment and easy separation functionality.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A tray-equipped pallet (2) includes a pallet (6), a tray (5), and a support plate (10). The tray (5) is made of a sheet and includes a rectangular bottom surface (50) secured to a top plate (62) of the pallet (6). The support plate (10) is secured to overlie the bottom surface (50) of the tray (5). The pallet (6) includes a connection portion (62a) that protrudes from an upper surface of the top plate (62) and to which the support plate (10) is secured. The tray (5) includes an engagement hole (57) that is formed in the bottom surface (50) and with which the connection portion (62a) engages, a first zipper portion (53) that enables separation of the bottom surface (50) into first and second bottom surface portions (50a and 50b), and a second zipper portion (54) that enables breakage of a part of the engagement hole (57) on an opposite side to the first zipper portion (53).