Pallet Assembly with Embedded Reinforcement for Hygienic Cleaning
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Solution Overview
Problem
Plastic pallets used in food applications face challenges in cleaning and contamination inspection due to trapped reinforcement members, which hinder efficient drainage and create pockets for dirt and moisture accumulation, while traditional methods like welding decks or adding reinforcement rods complicate cleaning and durability.
Innovation Solution
The pallet design incorporates reinforcement members entirely within one deck, using a series of over/under ribs and hollow round tubes to facilitate easy cleaning and drainage, with accessible surfaces and a weld joint for enhanced sanitation, and employs stainless steel or other materials for corrosion resistance and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcement members are trapped between the top deck and columns or between top deck and bottom deck/runners, then the pallet gains structural strength and durability, but cleaning becomes difficult due to created pockets and ledges that trap dirt and moisture
Solution Approach 1:
The reinforcement members are extracted from the traditional position between decks and columns, and instead are fully embedded within a single deck structure. This removal from the inter-deck space eliminates the creation of cleaning pockets while preserving structural strength through the deck-integrated reinforcement design.
Solution Approach 2:
The reinforcement members are repositioned from a three-dimensional space between decks to a two-dimensional plane within a single deck. This dimensional change allows the reinforcement to maintain structural integrity while eliminating vertical pockets that would trap contaminants, as the reinforcement now lies flat within the deck plane rather than creating vertical ledges.
2Strength
If traditional I-beam or rectangular tube reinforcement shapes are used, then the strength to weight ratio is optimized, but horizontal ledges and flat surfaces are created that trap contaminants and hinder drainage
Solution Approach 1:
The reinforcement members use round tube cross-sections instead of traditional I-beam or rectangular tube shapes. This curved, circular geometry eliminates horizontal ledges and flat surfaces where contaminants could accumulate, allowing cleaning solutions and water to flow smoothly around the reinforcement without creating trapping zones, while still providing adequate structural support.
3Reliability
If welding decks or adding reinforcement rods is done to make polyolefin pallets perform like wood, then durability and stiffness improve, but cleaning efficiency decreases due to created pockets and ledges
Solution Approach 1:
The reinforcement members are merged with the deck structure by being fully embedded within the deck material rather than being separate components between decks. This integration creates a unified smooth surface that maintains durability through reinforcement while eliminating the interfaces and gaps that would otherwise create cleaning pockets and reduce cleaning efficiency.
Data Source
AI summary
A pallet assembly includes an upper deck having a first plurality of ribs and a second plurality of ribs. The first plurality of ribs each include a first opening therethrough that opens downward. The second plurality of ribs each include a second opening therethrough that opens upward. The first openings and the second openings aligned to define a channel. A reinforcement member is disposed in the channel A plurality of columns extend from the deck.