Modular Pallet Segmentation for Volume and Weight Reduction
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Solution Overview
Problem
Existing pallet solutions, particularly wooden pallets, are inefficient in terms of volume usage during transport, costly due to weight and maintenance, and pose safety risks due to instability and non-recyclability, while adjustable pallets are expensive and complex.
Innovation Solution
A modular pallet system composed of interchangeable, recyclable parts with form-fitting connections such as dovetail joints, using injection molding for cost-effectiveness and high-impact strength, allowing for adjustable height and design for various applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wooden pallets are used to ensure stability and strength, then the pallet is reliable for transport, but the weight increases causing higher transportation costs
Solution Approach 1:
The pallet is divided into separate functional components: a lightweight base structure and interchangeable platform inserts. The base provides essential stability while the removable platforms add weight only when needed for specific load requirements, allowing optimization between weight and reliability.
Solution Approach 2:
The platform inserts are made from plastic material with adjustable thickness parameters (10mm to 50mm) to match different load requirements. This allows the pallet weight to be dynamically adjusted based on the specific transport needs while maintaining reliability when loaded.
2Volume of moving object
If adjustable pallets are used to reduce volume during transport, then volume efficiency improves, but the device complexity and cost increase significantly
Solution Approach 1:
The pallet system separates the base structure from the platform inserts, allowing the inserts to be removed and stored in the hollow space of the base. This simple segmentation enables volume reduction without complex mechanical adjustment mechanisms.
Solution Approach 2:
Instead of adjusting the pallet structure to change volume, the solution inverts the approach by removing components (platform inserts) entirely when not needed, and storing them within the pallet's own structure (hollow base), achieving volume efficiency through simplicity.
3Reliability
If wooden pallets are built to be stable for use, then the pallet reliability improves, but the weight increases and they must be discarded when damaged
Solution Approach 1:
The pallet is segmented into a durable base structure and replaceable platform inserts. When damage occurs, only the affected insert needs to be replaced rather than discarding the entire pallet, significantly reducing maintenance costs while maintaining reliability.
Solution Approach 2:
The modular design allows damaged platform inserts to be discarded and replaced with new or refurbished inserts, while the main pallet base is recovered and reused. This extends the overall pallet system life and reduces waste.
4Adaptability or versatility
If recyclable material is used for the pallet, then environmental sustainability improves, but the material must maintain high strength and stability
Solution Approach 1:
The pallet combines plastic material (recyclable) for the base structure with the possibility of using different materials for platform inserts. Plastic provides adequate strength while being recyclable, and the composite approach allows optimization of each component for its specific requirements.
Data Source
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AI summary
The invention proposes a modular pallet, the individual parts of which can be used to construct either a so-called transporting pallet or a so-called storage pallet. The transporting pallet is useable in the high-bay warehouse by an adapter 8 present in the high-bay warehouse being moved automatically beneath the transporting rail 7. Interchanging the intermediate component 6 (at least four of which are present in the pallet) makes it possible to change a storage pallet into a transporting pallet and the transporting pallet into a storage pallet.