A-Frame Pallet Assembly for Compact Building Kit Shipping
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Solution Overview
Problem
Manufacturers face challenges in shipping building kits due to large and cumbersome materials, leading to excessive shipping charges and labor-intensive unloading processes, which affect customer convenience and cost-effectiveness.
Innovation Solution
A pallet assembly with an A-shaped configuration that includes a base and upright supports, allowing for compact packaging and staged unloading of building materials, optimizing shipping dimensions to minimize charges and facilitate easy handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If building materials are shipped in traditional flat configurations, then shipping volume is large and cumbersome, but shipping charges increase and unloading becomes labor-intensive
Solution Approach 1:
The patent transforms building materials from traditional flat horizontal stacking to vertical upright positioning on the pallet assembly. Long materials like trim and molding are stood on their ends, utilizing the vertical dimension of the pallet structure. This dimensional change reduces the horizontal footprint and shipping volume while maintaining material accessibility for unloading.
Solution Approach 2:
The pallet assembly is divided into multiple upright supports (first upright support, second upright support, third upright support) that can independently hold different sets of building materials. This segmentation allows various materials to be organized in separate vertical zones, optimizing space utilization and facilitating selective unloading of specific material groups without moving others.
2Productivity
If building materials are stacked in compact arrangements, then shipping efficiency improves, but material accessibility for construction decreases
Solution Approach 1:
By positioning materials vertically rather than horizontally stacked, the invention achieves compact shipping arrangement while maintaining front-facing accessibility. Materials are arranged upright so that their ends or accessible portions face outward, allowing workers to easily access and remove materials during construction without unstacking or moving other materials.
Solution Approach 2:
The pallet assembly is pre-configured with upright supports positioned and dimensioned to hold specific materials in optimal orientations before shipping. The supports are designed with appropriate heights and spacing to present materials in construction-ready positions, eliminating the need for rearrangement or complex unloading operations at the construction site.
3Ease of operation
If pallet height is increased to accommodate long materials vertically, then material accessibility improves, but shipping cost increases due to excessive height
Solution Approach 1:
The pallet assembly uses upright supports of varying heights positioned at different locations (first, second, and third upright supports at different positions). Each support is locally optimized in height to accommodate the specific length requirements of materials placed on it, rather than using a uniform height throughout. This allows long materials to be vertically positioned for accessibility while keeping the overall pallet height within acceptable shipping limits.
Solution Approach 2:
The arrangement of upright supports creates an asymmetric profile on the pallet, with supports of different heights positioned strategically. This asymmetric configuration allows the pallet to efficiently accommodate materials of varying lengths in different zones, optimizing both material accessibility and overall height utilization without wasting vertical space or exceeding shipping height restrictions.
Data Source
AI summary
A pallet assembly and method of use for carrying a building kit. The pallet assembly includes a base, an A-frame operably engaged with the base, a first upright support of the A-frame operably engaged with the base at a first position defined at a first angle measured relative to the base, and a second upright support of the A-frame operably engaged with the base at a second position opposite to the first position and defined at a second angle measured relative to the base. The pallet assembly may also include a pair of cleats operably engaged with the base and spaced apart from the A-frame.