Pallet Deck Opening and Brace for Product Removal
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Solution Overview
Problem
Conventional pallets do not efficiently allow for the removal of products from boxes without requiring the box to be completely removed, especially when the products are smaller than the opening, leading to inefficiencies in unloading and handling.
Innovation Solution
A pallet design featuring a central opening that allows access to the box from below, along with snap-fit corner caps and hingably connected retainers, enables the unloading of products through the opening without removing the box, and the use of a brace system to secure and support goods on multiple pallets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional pallet design without opening is used, then the box is securely supported on the pallet, but the products cannot be removed without completely removing the box
Solution Approach 1:
The pallet deck is segmented by introducing a central opening that divides the deck into peripheral and central regions. This segmentation allows products to be accessed and removed from the box through the opening without removing the entire box from the pallet, thereby improving product removal ease while maintaining overall structural integrity through the peripheral wall.
Solution Approach 2:
A central opening is extracted from the solid deck structure, creating an access pathway through the pallet. This extracted opening enables direct access to products within the box from below the pallet, allowing product removal without complete box removal, thus resolving the contradiction between ease of operation and structural complexity.
2Ease of operation
If a large opening is created in the deck, then product access is improved, but the structural strength of the deck is reduced
Solution Approach 1:
The deck structure is modified with a peripheral wall that extends downward from the periphery of the opening. This creates a local quality enhancement where the peripheral wall provides concentrated structural support around the opening, compensating for the strength reduction caused by the large opening while maintaining product access ease.
Solution Approach 2:
The peripheral wall is designed beforehand to compensate for the structural weakness introduced by the opening. By providing this preemptive structural reinforcement, the deck maintains sufficient strength to support loads despite the large central opening that facilitates product access.
3Stability of the object's composition
If corner caps are used to secure the box, then the box is firmly attached to the pallet, but the unloading process becomes more complex
Solution Approach 1:
The corner caps are designed with self-centering features that allow them to automatically align and secure to the deck corners without requiring complex alignment procedures. The caps engage with the deck and box corners in a self-service manner, providing firm attachment stability while minimizing the complexity of the securing mechanism through intuitive, tool-free installation.
Data Source
AI summary
A pallet includes a deck having an opening therethrough, such that product can be removed through the opening from a box loaded on the deck of a pallet. A plurality of columns support the deck. The box may be supported on the deck over the opening. The bottom wall of the box may be opened though the opening in the deck. The items can then be removed from the box through the opening through the deck without removing the box from the pallet. Optionally, fasteners may secure flaps of the box in corners of the deck of a pallet. According to another feature, a brace having an elongated body portion can be secured to an opening of the pallet, such that the elongated body portion abuts goods that are supported on the deck.