Plastic Pallet Positioning Elements Protection
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Solution Overview
Problem
Modern plastic pallets made of materials like HDPE lack sufficient friction and protection for positioning elements, leading to wear and damage when used with heavy loads, especially when stacked, as existing solutions like rubber studs and raised deck areas are inadequate for preventing movement and toppling.
Innovation Solution
A plastic pallet design featuring an upper and lower deck with support elements, where the lower deck includes positioning elements protected by protruding protection elements made of wear-resistant materials that prevent direct contact with the ground, maintaining effectiveness throughout the pallet's service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If positioning elements are provided on the lower deck to stabilize loads, then load stability is improved, but the positioning elements are susceptible to wear and damage from direct ground contact
Solution Approach 1:
The patent introduces protection elements as intermediary structures between the positioning elements and the ground. These protection elements extend below the lower deck surface and make contact with the ground first, thereby mediating the harmful interaction between the ground and the positioning elements. This allows the positioning elements to fulfill their load stabilization function while being shielded from direct ground contact that causes wear and damage.
Solution Approach 2:
The protection elements are designed to protrude below the lower deck surface in advance, creating a protective barrier before the positioning elements can contact the ground. This beforehand cushioning approach ensures that the vulnerable positioning elements are preemptively protected from wear and damage by having the protection elements absorb the ground contact first.
2Force
If rubber studs are added to increase friction, then fork lift prong slipping is prevented, but the studs are easily damaged by heavy loads
Solution Approach 1:
The patent applies different material properties to different parts of the pallet system. Rubber studs are applied locally to the upper deck surface where high friction is needed to prevent fork lift prong slipping. The protection elements on the lower deck are made of wear-resistant materials suitable for ground contact. This local quality approach allows each component to have optimized properties for its specific function and location.
3Stability of the object's composition
If raised deck areas are provided for positioning, then cask sliding is prevented, but the preventive action is limited to bottom parts only
Solution Approach 1:
The patent extends the positioning function from a single dimension (raised areas on the upper deck for bottom contact) to multiple dimensions by adding protection elements with positioning protrusions on the lower deck. This allows positioning contact at both the top and bottom of casks, creating a more comprehensive three-dimensional positioning system that prevents sliding more effectively.
Data Source
Figure 1~3
AI summary
A plastic pallet (1) has an upper deck (2), a lower deck (3) and support elements (4) connecting the decks. The underside (9) of the lower deck is provided with positioning elements, such as curved protrusions and/or recesses, for positioning casks or barrels of a lower pallet in a stack. The lower deck (3) is further provided with protection elements (6) which in use extend below the positioning elements in the underside of the lower deck.