Plastic Pallet Support Blocks With Forklift Tine Pockets
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Solution Overview
Problem
Plastic pallets used with forklift equipment face durability and strength issues due to wear from repeated contact with metal tines, leading to damage and costly replacements, especially when the top deck separates from the bottom deck.
Innovation Solution
The design incorporates corner support blocks with recessed pockets to allow forklift tines to grip and spin the pallet without damaging the support blocks, and snap-pins that break under excessive force to prevent top deck separation, allowing for partial replacement instead of the entire pallet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pallet is made from plastic material, then durability and strength are improved compared to wood, but the support blocks are still subjected to intense wear from repeated contact with sharp metal tines
Solution Approach 1:
The support blocks incorporate localized reinforcement features including ribs extending between pockets, thickened regions at stress points, and strategically positioned structural elements that concentrate strength where the metal tines apply force, while other areas maintain the inherent flexibility of plastic material
2Ease of operation
If the tines are inserted too far between the decks, then the top deck separates from the bottom deck causing damage, but allowing sufficient insertion depth is needed for proper forklift operation
Solution Approach 1:
The support blocks include pre-formed pockets that guide and limit the insertion depth of the metal tines before they reach critical positions. These pockets are positioned to engage the tines at an optimal depth, preventing excessive insertion that would cause deck separation while still allowing sufficient insertion for proper forklift operation
Solution Approach 2:
The pockets act as intermediary structures between the metal tines and the support blocks, providing a controlled interface that manages the force transmission. The pockets guide the tines and distribute the insertion force across a larger area, preventing concentrated loads that would cause deck separation
3Ease of repair
If the support blocks are damaged by the pallet jack, then they can be replaced at lower cost than the entire pallet, but the damage from tine insertion still compromises structural integrity
Solution Approach 1:
The support blocks are designed as separate, replaceable components positioned at critical locations between the top and bottom decks. This segmentation allows individual support blocks to be replaced if damaged, rather than replacing the entire pallet structure, while the distributed arrangement of multiple support blocks maintains overall structural integrity even when some blocks are damaged or being replaced
Data Source
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AI summary
A pallet includes a top deck having a rectangular shape, a bottom deck having a rectangular shape, and spaced apart corner support blocks coupled between corners of the top and bottom decks and forming a gap therebetween for receiving a lifting member. Each corner support block includes a pair of exposed side surfaces aligned with a respective corner, with each exposed side surface having a pocket formed therein for receiving an end of the lifting member so as to allow the pallet to be spun around.