Pallet Assembly With Recessed Deck And Overhang
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Solution Overview
Problem
Conventional pallets lack efficient load distribution and stability during transportation and storage, especially when stacking larger containers like barrels, leading to potential instability and difficulty in maneuverability.
Innovation Solution
The pallet design features an upper deck with recessed aligning impressions and extended legs, allowing for precise placement and balancing of containers, along with a lower structure that mates with the upper deck to enhance rigidity and support, enabling better load distribution and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pallets are used for transporting and stacking containers, then the basic transportation function is fulfilled, but load distribution and stability are insufficient, especially when stacking larger containers like barrels
Solution Approach 1:
The upper deck is segmented into multiple recesses, each designed to accommodate specific containers. This segmentation provides predetermined locations for containers, ensuring proper load distribution and stability without requiring an overly complex overall structure.
Solution Approach 2:
The pallet features localized structural enhancements including recesses with lower support surfaces and extended legs at specific positions. These local quality improvements provide targeted support where needed while maintaining simplicity in other areas of the pallet structure.
2Productivity
If containers are placed without predetermined locations on the pallet, then loading flexibility is maintained, but loading time increases and stability decreases
Solution Approach 1:
The recesses are pre-formed in the upper deck at predetermined locations, preparing the pallet in advance for container placement. This preliminary action guides operators to place containers correctly and quickly without requiring complex positioning procedures during loading.
Solution Approach 2:
The recesses with lower support surfaces automatically guide and secure containers in the correct position once placed. The structure serves itself by providing built-in alignment and positioning features that eliminate the need for additional positioning operations.
3Ease of operation
If the upper deck is positioned directly above the legs, then structural simplicity is maintained, but load distribution and maneuverability are compromised
Solution Approach 1:
The upper deck is positioned asymmetrically relative to the legs, with an overhang extending beyond the leg structure. This asymmetric configuration improves maneuverability by providing clearance for forklift tines and other handling equipment while maintaining structural simplicity through the basic leg-deck arrangement.
Data Source
AI summary
A pallet includes an upper portion having an upper surface for supporting containers thereon. A first plurality of recesses in the upper surface have a first lower support surface spaced from the upper surface. A plurality of legs extend downwardly from the upper portion. The upper portion includes an overhang extending outward from one of the plurality of legs extending along each side of the pallet. In a disclosed method, containers are nested in a predetermined location on an upper surface of the pallet.