A-Frame Pallet Assembly for Compact Building Kit Shipping
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Solution Overview
Problem
Manufacturers face challenges in shipping large and cumbersome building kits due to high shipping costs and labor-intensive unloading processes, necessitating more efficient packaging solutions.
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, with specific angles and cleats to support and secure materials during transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If building materials are packaged in large and cumbersome freight, then complete building kits can be delivered, but shipping costs and freight charges increase excessively
Solution Approach 1:
The patent applies nesting by placing building materials vertically within the A-frame structure, where materials are nested inside the frame configuration. This allows complete building kits to be delivered in a compact arrangement that fits within standard shipping dimensions, thereby reducing excessive shipping costs while ensuring complete kit delivery.
Solution Approach 2:
The patent transitions from horizontal stacking to vertical arrangement of building materials within the A-frame. This dimensional change allows materials to be organized upright, maximizing space utilization and reducing the overall footprint, which eliminates the need for large and cumbersome freight while maintaining complete kit delivery.
2Quantity of substance
If building materials are shipped in large freight, then complete building kits can be delivered, but additional assistance and labor are needed for unloading
Solution Approach 1:
The patent segments building materials into organized sections within the A-frame structure, with different materials positioned at different heights and locations. This segmentation allows for systematic unloading where materials can be accessed in an organized manner, reducing the need for additional assistance and labor compared to unloading from large, cumbersome freight.
Solution Approach 2:
The patent applies preliminary action by pre-arranging building materials in a predetermined sequence and position within the A-frame during packaging. This pre-organization enables efficient unloading where materials can be removed in the intended construction sequence, reducing labor requirements and eliminating the need for additional assistance during the unloading process.
3Loss of energy
If building materials are packaged compactly, then shipping costs are reduced, but loading and unloading efficiency may be compromised
Solution Approach 1:
The A-frame structure serves multiple functions: it provides a compact packaging configuration that reduces shipping costs, while simultaneously enabling efficient loading and unloading through its open design and standardized dimensions. The universal A-frame can accommodate various building materials and is compatible with standard handling equipment, thus maintaining productivity while achieving compact packaging.
Solution Approach 2:
The patent applies dynamics by designing the A-frame as an open, accessible structure that allows flexible loading and unloading operations. The dynamic design enables materials to be easily inserted and removed from different angles, maintaining high productivity during loading and unloading while achieving compact packaging configuration that reduces shipping costs.
4Ease of manufacture
If upright supports are positioned at standard angles, then manufacturing is simplified, but accommodation of long and cumbersome materials is limited
Solution Approach 1:
The patent applies parameter changes by varying the angles of the upright supports from standard configurations to optimized angles that maximize the accommodation of long and cumbersome materials. This parameter adjustment allows the support frame to hold extended materials at appropriate inclines while maintaining manufacturability through standard fabrication techniques for non-standard angles.
Solution Approach 2:
The patent applies asymmetry by positioning upright supports at different angles rather than symmetric standard angles. This asymmetric configuration optimizes the space utilization for long and cumbersome materials, allowing them to be accommodated at appropriate inclines while the supports remain manufacturable using standard angular measurements.
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.