Pallet Base Reinforcement with Detachable Skids
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Solution Overview
Problem
Existing pallet bases face challenges in ensuring safety during loading and storage, particularly in high-bay warehouses, where they are subjected to bending stress, and require cost-effective production methods while maintaining stability and ease of assembly.
Innovation Solution
The design incorporates skid parts made of plastic with fork openings for stable positioning and reinforcement, along with a detachable insert that can be made of metal or reinforced plastic, enhancing bending resistance and allowing for easy replacement, and a twin-sheet process for manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the base plate is made thinner to reduce weight and cost, then manufacturing cost decreases, but bending resistance and structural strength deteriorate
Solution Approach 1:
The base plate combines plastic material with integrated insert parts made of different materials (metal, wood, or different plastic types) to create a composite structure. This allows the thin plastic base plate to gain enhanced bending resistance from the insert parts while maintaining low weight and manufacturing cost.
Solution Approach 2:
Instead of making the entire base plate thicker, insert parts are strategically placed at specific locations where bending stress occurs (such as center and corner regions). This local reinforcement approach provides necessary strength only where needed, keeping the overall base plate thin and cost-effective.
2Quantity of substance
If the base plate is made thinner to reduce material usage, then material cost decreases, but stability during storage in high-bay warehouses deteriorates
Solution Approach 1:
The thin plastic base plate is combined with rigid insert parts to create a composite structure that achieves sufficient bending stiffness and stability for high-bay warehouse storage without requiring excessive plastic material.
Solution Approach 2:
Insert parts are positioned at critical locations (center and corners) to provide localized reinforcement that prevents deformation during storage, allowing the majority of the base plate to remain thin and material-efficient.
3Ease of repair
If skid components are made detachable to facilitate repair and replacement, then ease of repair improves, but device complexity increases
Solution Approach 1:
The base plate is segmented into modular components: the main plastic base plate, detachable insert parts, and skid components. Each can be independently replaced based on wear or damage, simplifying repair operations while maintaining a manageable overall structure.
Solution Approach 2:
The connection between skid components and the base plate is designed to be detachable rather than permanent, allowing the skids to be removed and reattached as needed. This dynamic connection facilitates easy replacement while the standardized interface keeps assembly complexity low.
Data Source
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AI summary
The invention relates to a pallet base (2) for a transport container (1) comprising a base plate manufactured from a thermoformable plastic material using a twin-sheet process and consisting of at least two shells with an inner shell and an outer shell, and an insert provided for reinforcing the base plate, as well as several foot sections detachably attached to an underside of the base plate. According to the invention, at least two foot sections are provided, each in the form of a skid made of plastic, which has a contact surface extending over the length of the underside and at least one fork opening for inserting a fork tine.A transport container according to the invention comprises such a pallet base (2) and a folding wall ring (3) that surrounds the pallet base in a ring shape, which is manufactured from a deep-drawable plastic material using a twinsheet process and is constructed with at least two shells, an inner shell and an outer shell.