Two-Part Composite Pallet with Internal Channel
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Solution Overview
Problem
Existing loading pallets have complex manufacturing processes and require multiple molds, leading to increased production time and costs, making it difficult to modify dimensions and achieve efficient handling with forklifts.
Innovation Solution
A loading pallet designed in two identical portions that can be manufactured using a single mold, with a main internal channel for forklift support and optional secondary channel, reinforced with ribs for mechanical strength, and made from composite materials like carbon fibers and poly epoxy, allowing easy assembly and modification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a loading pallet is manufactured as a single complex piece, then the structural integrity is maintained, but the manufacturing time and cost increase significantly
Solution Approach 1:
The pallet is divided into two identical portions that are secured to each other at an interface plane. Each portion can be manufactured separately using a single mold, reducing manufacturing complexity and time while maintaining the overall structural integrity of the assembled pallet.
2Manufacturing precision
If multiple molds are used to manufacture different parts of the pallet, then the manufacturing precision is improved, but the device complexity and cost increase
Solution Approach 1:
A single mold is designed to manufacture both identical portions of the pallet. The mold can be repositioned or reconfigured to produce either portion, eliminating the need for multiple specialized molds while maintaining manufacturing precision through consistent tooling.
3Strength
If the pallet is made with thick walls for strength, then the mechanical strength is improved, but the weight increases unnecessarily
Solution Approach 1:
The pallet structure incorporates varying wall thicknesses optimized for local requirements. Thinner walls are used where strength requirements are lower, while thicker sections or reinforcing ribs are placed strategically at high-stress areas, achieving adequate mechanical strength with reduced overall weight.
4Ease of operation
If the internal channel is made large to accommodate forklift support, then the ease of operation is improved, but the structural strength may be compromised
Solution Approach 1:
The pallet is constructed from composite materials that provide high strength-to-weight ratio, allowing for larger internal channels that accommodate forklift support while maintaining adequate structural strength. The composite structure compensates for the reduced material volume in areas where large channels are present.
Data Source
Figure 1~2
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Figure 5~6
AI summary
The invention relates to a pallet (1) which is intended to be secured to an object (9) in order to facilitate the handling of said object (9). According to the invention, the pallet is made of two identical portions (14, 15) which are secured to one another at an interface plane delimiting a main internal channel (16).