Dismantlable Pallet Structure Using Interlocking Longitudinal and Cross Members
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Solution Overview
Problem
Existing pallet structures require additional connecting elements or materials for assembly, leading to increased costs, manufacturing drawbacks, and transportation inefficiencies due to protrusions and complexity, making them uneconomical for long-distance hauls and difficult to recycle.
Innovation Solution
A self-assembly structure composed of two types of parts, longitudinal and cross members with specific slot configurations allowing assembly without additional elements, using L-shaped slots and narrowed segments for secure engagement, ensuring solidity and ease of handling without protrusions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional connecting elements are used to assemble pallet structures, then the structural strength and rigidity are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the connecting element and the structural member into a single integrated component. The L-shaped slot is directly formed as part of the structural member, eliminating the need for separate connecting elements like rods or fasteners. This merging reduces device complexity while maintaining structural integrity through the geometric interlocking design.
Solution Approach 2:
The L-shaped slot acts as an intermediary geometric feature that enables connection without additional elements. The narrowed segment of the cross member serves as a mediator that fits into the L-shaped slot, creating a secure connection through shape complementarity rather than through separate fastening components.
2Reliability
If additional connecting elements are used for assembly, then the reliability of connections is improved, but the loss of substance and manufacturing cost increase
Solution Approach 1:
By integrating the connection feature directly into the structural member through the L-shaped slot, the patent eliminates the need for separate connecting elements. This reduces material consumption and waste associated with producing, transporting, and assembling additional components, while maintaining reliable connections through the geometric interlocking design.
3Ease of repair
If protrusions are added to enable dismantlable assembly, then the ease of repair and replacement is improved, but the ease of operation and handling deteriorates
Solution Approach 1:
Instead of adding protrusions that extend outward, the patent inverts the approach by creating recesses (L-shaped slots) that receive the narrowed segments. This inversion allows the connection features to be recessed into the members rather than protruding outward, maintaining ease of handling while enabling easy assembly and disassembly through the complementary geometric shapes.
4Ease of operation
If complex slot configurations are used for self-assembly, then the ease of operation is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The L-shaped slot and narrowed segment use asymmetric geometric configurations that guide assembly through shape complementarity. The asymmetric L-shape with its vertical and horizontal portions, combined with the narrowed segment dimensions, creates a self-aligning connection that is easy to assemble while requiring standard manufacturing tolerances rather than high-precision machining.
Data Source
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AI summary
The invention relates to a self-assembly formed by a series of longitudinal members and cross members, all of the longitudinal members being identical to one other and all of the cross members being identical to one other, such that only two types of parts are required to construct the structure. Owing to the shape of the parts, they can be assembled to one another to create a solid structure without requiring any other connecting materials or elements. The longitudinal members comprise a series of slots into which narrowed segments of the cross members are inserted. Once the cross members have been inserted into the slots they are trapped therein by moving the longitudinal members and, in order to prevent this movement occurring in the opposite direction, other cross members are inserted into slots provided in the longitudinal members for this purpose.