Pallet Support Convexes for Fork Insertion and Article Stability
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Solution Overview
Problem
Existing pallet designs face issues with articles being dropped during transportation due to insufficient support convex height and interference with fork insertion operations during pallet stacking, especially with recent trends of weight and thickness reduction.
Innovation Solution
A pallet configuration with a lower deck thickness less than the upper deck, featuring support convexes that match the lower deck thickness in the insertion region and are taller in other areas, along with reinforcement ribs to enhance rigidity and prevent deformation, allowing for efficient fork insertion and reduced article drop-off risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the height of support convexes is increased to prevent article drop-off, then article stability is improved, but fork insertion operation is interfered with during pallet stacking
Solution Approach 1:
The support convexes are designed with different heights in different regions: a first height in the insertion-corresponding region that matches the lower deck thickness to avoid fork insertion interference, and a second height greater than the first height in other regions to provide sufficient article support. This local differentiation resolves the contradiction between article stability and fork insertion operability.
2Weight of moving object
If the thickness of the lower deck is reduced for weight reduction, then pallet weight is decreased, but the height of support convexes becomes insufficient to prevent article drop-off
Solution Approach 1:
The support convexes have extended portions that protrude from the upper surface of the lower deck, with heights differentiated by region. In non-insertion regions, the support convexes have a second height greater than the lower deck thickness, providing sufficient article support even when the lower deck thickness is reduced for weight reduction purposes.
3Ease of operation
If the height of support convexes is reduced to avoid fork insertion interference, then fork insertion operability is improved, but article support capability deteriorates
Solution Approach 1:
The support convexes are designed with region-specific heights: in the insertion-corresponding region, the height matches the lower deck thickness to ensure fork insertion operability, while in other regions, the height exceeds the lower deck thickness to maintain adequate article support capability.
4Productivity
If the overall pallet height is reduced for space efficiency, then storage efficiency is improved, but the height of support convexes becomes insufficient to prevent article drop-off
Solution Approach 1:
The support convexes have extended portions that protrude from the upper surface of the lower deck, with heights differentiated by region. This allows the overall pallet height to be reduced for storage efficiency while maintaining sufficient article support in non-insertion regions where the support convexes have greater height.
Data Source
AI summary
A pallet includes columns, an upper deck, and a lower deck. The upper deck links upper ends of the columns such that upper surfaces of the columns and upper deck form an upper deck surface. The lower deck links lower ends of the columns such that lower surfaces of the columns and lower deck form a lower deck surface. Fork insertion structures receive forks of a lift apparatus inserted thereto from four sides of the pallet. Outer circumferential projections are formed along a peripheral edge of the upper deck surface, including an extended portion extending outward from the peripheral edge, and a support portion protruding upward from the extended portion. The support portion has a first height in an insertion-corresponding region, and a second height in a general region, the first height being equal to a thickness of the lower deck, the second height being greater than the first height.