Modular Pallet Design for Cost Reduction and Repair
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Solution Overview
Problem
Conventional plastic pallets have high manufacturing costs due to expensive molds and low usage rates because they become useless when damaged, even with minor damage.
Innovation Solution
A modular pallet design comprising orthogonally oriented first and second base members, central base members, connecting bars, and a loading plate, allowing for adjustable size and easy replacement of damaged components, reducing manufacturing costs and extending the pallet's lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional plastic pallets are integrally formed using expensive molds, then manufacturing precision and structural strength are improved, but manufacturing cost increases
Solution Approach 1:
The pallet is divided into multiple independent base members (first base members with fixing grooves, second base members with fixing grooves and slots, central base member with central slots) that can be manufactured separately using simple molds and then assembled together using connecting bars, eliminating the need for expensive large-scale integral molding while maintaining structural strength
Solution Approach 2:
Multiple separately manufactured base members are combined through connecting bars that fit into fixing grooves and slots to form an integrated pallet structure, achieving both cost reduction through separate manufacturing and structural integrity through the combined assembly
2Strength
If conventional plastic pallets are designed as integral structures, then structural strength is improved, but ease of repair deteriorates because the entire pallet becomes useless when damaged
Solution Approach 1:
The pallet structure is segmented into replaceable base members that can be independently replaced when damaged, allowing the undamaged portions to remain in use and significantly extending the overall service life of the pallet system
Solution Approach 2:
Damaged base members can be discarded and replaced with new or refurbished units while the remaining functional base members are recovered and continue to serve, maximizing the utilization period of the pallet
3Manufacturing precision
If conventional plastic pallets use fixed-size molds, then manufacturing precision is improved, but adaptability deteriorates when different sizes are needed
Solution Approach 1:
The pallet is segmented into standardized base members that can be arranged in different configurations to create various pallet sizes, allowing the same precision molds to produce components for multiple pallet dimensions
Solution Approach 2:
The base members are designed with universal fixing grooves and slots that can accommodate different connecting bar arrangements, enabling the same components to serve multiple pallet size requirements
Data Source
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AI summary
A pallet (9) includes first base members (20), second base members (30), a central base member (10), connecting bars (60A), and a loading plate (8A). The connecting bars (60A) secure the base members (10, 20, 30) to form a pallet frame (1). The loading plate (8A) is fixed on the pallet frame (1). The size of the pallet (9) can be adjusted in length and width. Therefore, the size of the pallet (9) can be adjusted freely and conveniently according to practical requirements. Consequently, the cost for manufacturing the pallet (9) can be reduced. In addition, when one base member (10/20/30) is damaged or missing, the damaged or missing base member (10/20/30) can be replaced by a new base member (10/20/30). Therefore, the pallet (9) can be used for more times, allowing the cost reduction in manufactory. Furthermore, the base members (10, 20, 30) and the connecting bars (60A) are connected with each other to form the pallet frame (1) which is rigid and has high structural strength, such that the pallet frame (1) would not deform and is safe when used for handling and transporting materials.