Asymmetric Fork Tube Risers for Metal Pallets
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Solution Overview
Problem
Metal pallets face challenges due to high initial cost and weight, as well as susceptibility to damage from fork truck usage, which can lead to unsafe stacking conditions and reduced load-carrying capacity when made from heavier materials like stainless steel or aluminum, while lighter-gauge metal options compromise on load-carrying capacity and racking resistance.
Innovation Solution
A sheet metal pallet design featuring asymmetric fork tube risers with distinct outer and inner angles, along with transverse and longitudinal girding, enhances resistance to shear loads and deflection, allowing for manufacturing from lightweight sheet metal while maintaining structural integrity and load-carrying capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heavier metal materials (stainless steel or aluminum) are used to manufacture pallets, then strength and durability are improved, but weight increases and cost increases
Solution Approach 1:
The patent applies different thicknesses and configurations of metal sheeting in different locations of the pallet structure. The deck uses specific gauge metal with reinforcement ribs at strategic locations, while the risers use appropriately sized angles and channels. This local variation in material properties optimizes strength where needed while minimizing weight in less critical areas, resolving the contradiction between overall strength and total weight.
Solution Approach 2:
The pallet is divided into distinct functional components (deck, risers, reinforcement elements) that can be independently optimized. The deck is segmented with reinforcement ribs, and the risers are designed as separate angle or channel sections. This segmentation allows each component to be engineered for its specific load requirements rather than using uniformly heavy material throughout the entire structure.
2Ease of manufacture
If lighter-gauge metal is used to reduce weight and cost, then manufacturing cost and weight are reduced, but load-carrying capacity and racking resistance decrease
Solution Approach 1:
The patent incorporates reinforcement ribs and strategically positioned girding elements during the initial manufacturing process. These reinforcement features are built into the light-gauge metal deck before final assembly, allowing the use of thinner, cheaper metal while maintaining structural integrity through pre-planned reinforcement at critical stress points.
Solution Approach 2:
The pallet combines light-gauge metal decking with reinforcement ribs and girder elements to create a composite structure. This composite approach allows the base material to be lightweight and inexpensive while the added reinforcement elements provide the necessary strength and stiffness, achieving both cost reduction and maintained load capacity.
3Device complexity
If traditional symmetric fork tube riser design is used, then manufacturing simplicity is maintained, but resistance to racking forces and shear loads is insufficient
Solution Approach 1:
The patent employs asymmetric reinforcement patterns in the fork tube risers, using different angle sizes or channel configurations on the inner and outer faces. This asymmetry is specifically designed to counteract the asymmetric loading patterns that occur during racking events and forklift insertion, providing enhanced resistance to shear and lateral forces while maintaining reasonable manufacturing complexity.
Solution Approach 2:
The reinforcement ribs extend in multiple dimensions from the deck surface, creating a three-dimensional reinforcement structure. This multi-dimensional approach to reinforcement provides strength in multiple load directions simultaneously, improving racking resistance without requiring proportionally heavier materials throughout the entire structure.
Data Source
AI summary
A sheet metal pallet assembly includes a deck and an undercarriage. The deck is reinforced about its outer edges by longitudinal and transverse perimeter girding. The deck is further reinforced by one or more transverse reinforcement ribs and interior longitudinal girding. The undercarriage is composed of left and right fork tube risers joined together by bridges. The fork tube risers are configured to receive the tines of a forklift. Each fork tube riser has inner and a outer legs, each splayed at an a respective angle. Preferably, the splay angle of the outer leg is greater than the splay angle of the inner leg. The ends of each fork tube riser are folded over with a hem to improve strength and present a blunt edge. The undercarriage may, optionally, be fabricated from a single monolithic piece of sheet metal.