Configurable Pallet With Plastic-Cardboard Bases For Custom Loads
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Solution Overview
Problem
Conventional pallets are heavy, expensive, and often not durable, leading to high costs for repair or replacement, and they are not easily customizable to fit specific shipping configurations, resulting in inefficient storage and transportation.
Innovation Solution
A configurable pallet system comprising a plastic base with protrusions and a cardboard base with openings, allowing for customizable load-bearing platforms that can be assembled to fit specific dimensions, reducing weight and storage space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional pallets are made from wood or plastic with standardized sizes, then they provide sufficient load-bearing capacity and durability, but they become heavy, expensive, and difficult to customize for specific shipping configurations
Solution Approach 1:
The pallet is divided into separate modular components: a base layer, a load distribution layer with voids, and a top layer. This segmentation allows each component to be optimized independently and enables customization by selecting different combinations of modules for specific shipping configurations, while reducing overall material usage and weight compared to solid conventional pallets.
Solution Approach 2:
The load distribution layer incorporates voids and a porous structure that reduces material consumption and overall weight while maintaining load-bearing capacity. The voids are strategically positioned to provide structural support where needed while minimizing material usage, allowing customization without adding unnecessary weight.
2Adaptability or versatility
If standardized pallet sizes are used, then they meet industry standards and are readily available, but they result in inefficient storage and transportation when specific shipping configurations require different dimensions
Solution Approach 1:
By segmenting the pallet into modular layers and components, the system enables customization of dimensions and configurations to match specific shipping needs. This eliminates the need to store multiple standardized pallet sizes, as a single modular system can be configured for different dimensions, significantly reducing storage space requirements for empty pallets.
Solution Approach 2:
The modular design allows the pallet configuration to be dynamically adjusted based on specific shipping requirements. Components can be reconfigured or replaced to match different dimensions and load requirements, providing adaptability without requiring a inventory of various standardized pallet sizes.
3Ease of manufacture
If conventional pallets are designed for durability and repairability, then they can be reused multiple times, but they become expensive to purchase and maintain
Solution Approach 1:
Segmenting the pallet into separate layers and components allows each part to be manufactured using cost-effective materials and processes appropriate to its specific functional requirements. The load distribution layer with voids uses less material, reducing cost, while maintaining necessary strength through strategic structural design. Damaged components can be replaced individually rather than replacing the entire pallet.
Solution Approach 2:
The pallet employs composite construction with different materials optimized for specific functions: the base layer provides structural support, the load distribution layer with voids provides strength-to-weight optimization, and the top layer provides load-bearing surface. This composite approach achieves necessary strength while reducing material costs and improving recyclability of individual components.
Data Source
AI summary
This disclosure provides a configurable pallet or load-bearing platform, such as a pallet, for supporting goods. The load-bearing platform may include one or more plastic bases having two or more protrusions connected by one or more bridge pieces. The two or more protrusions are spaced apart one or more distances. The load-bearing platform further includes a cardboard base having openings spaced apart an amount wherein the openings are configured to receive the two or more protrusions of the plastic base. A load distribution member may be included and configured to contact at least a portion of the plastic base. The load distribution member may support at least a portion of the goods and distributes at least a portion of the weight of the goods to at least a portion of the plastic base. The size of the cardboard base, as well as other components of the load-bearing platform, in certain implementations, may be customized on demand.