Palletless Gas Cylinder Array Handling via Tunnel Elements
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Solution Overview
Problem
Conventional systems for packaging and shipping gas cylinders, such as propane tanks, are inefficient in space usage, pose safety risks during unpackaging, and rely on excessive plastic wrapping, leading to increased costs and waste.
Innovation Solution
A palletless system where a three-dimensional array of gas cylinders is formed from vertically-stacked two-dimensional subarrays, using recyclable materials and tunnel elements to allow forklift engagement, reducing the need for pallets and enhancing safety and protection during shipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a pallet is placed under the array to facilitate lifting by a forklift, then the array can be easily moved and stacked, but the pallet adds height to the overall shipment package, restricting the number of gas cylinders which can fit vertically within a typical shipping truck or container
Solution Approach 1:
The invention extracts and eliminates the pallet from the shipping system entirely. Instead of placing a pallet under the array for forklift lifting, the system uses the gas cylinders themselves and their handling components (handles, feet, and array components) as the lifting interface, removing the unnecessary component that consumes valuable vertical shipping space.
Solution Approach 2:
The gas cylinders and array components serve their own lifting function without requiring an external pallet. The handles on the cylinders and the array structure itself provide the necessary interfaces for forklift tongs to engage and lift the array directly, making the system self-sufficient and eliminating the need for additional lifting aids.
2Productivity
If the array is made five gas cylinders high to maximize vertical space utilization, then more cylinders can be shipped, but a worker requires a ladder to access and remove the upper level of tanks during unpackaging, presenting an undesirable safety risk
Solution Approach 1:
The invention incorporates preliminary action by designing the array with built-in lifting interfaces (tunnel elements, handles, and feet) that enable forklift access at multiple elevations. This preliminary design feature allows the entire array or upper sections to be mechanically lifted and positioned during unpackaging, eliminating the need for workers to climb ladders to access upper levels.
Solution Approach 2:
The invention introduces intermediary components (array components with tunnel elements and handling features) that mediate between the forklift and the gas cylinders at upper levels. These intermediaries enable mechanical manipulation and positioning of upper cylinders without direct human contact at height, transferring the lifting function from human workers to forklift equipment.
3Reliability
If conventional systems use expansive amounts of plastic wrapping to secure the array of propane tanks together during shipment, then the tanks are protected from movement and damage, but packaging costs increase and waste materials are generated
Solution Approach 1:
The invention extracts and eliminates the plastic wrapping from the securing system. Instead of using expansive plastic materials to secure the array, the system relies on the mechanical interlocking of array components, the nested engagement of handles and feet, and the structural integrity of the cylinder arrangement itself to prevent movement and damage during shipment.
Solution Approach 2:
The invention replaces expensive and wasteful plastic wrapping with reusable array components and handling features that are integrated into the cylinder structure. These components (tunnel elements, handles, feet) are designed to be durable and reusable across multiple shipping cycles, eliminating the need for single-use plastic materials.
4Loss of substance
If recyclable materials like cardboard are used to form the array components instead of plastic, then packaging costs are reduced and waste is minimized, but the rigidity and structural strength may be insufficient to protect the gas cylinders
Solution Approach 1:
The invention employs composite material strategies by combining recyclable materials (cardboard, paperboard) with the inherent strength of the gas cylinders themselves. The array components are designed to work in conjunction with the cylinder structure, using the cylinders as the primary load-bearing elements while the recyclable components provide structural organization, spacing, and handling functionality.
Solution Approach 2:
The invention segments the structural function across multiple elements: the gas cylinders provide their own structural integrity, the array components (made from recyclable materials) provide spacing and organization, and the handling features (handles, feet, tunnel elements) provide mechanical engagement points. This segmentation allows each component to be optimized for its specific function while using environmentally friendly materials.
Data Source
AI summary
A system and method are provided for palletless shipment of gas cylinder arrays. A three-dimensional array of gas cylinders is formed from a plurality of vertically-stacked two-dimensional subarrays. First elongated voids extend through the array in a width direction at a first handle elevation. Second elongated voids extend through the array in a depth direction at a second handle elevation. The first and second elongated voids are bilaterally bounded by handle portions of adjacent gas cylinders, and vertically bounded by upper and lower surfaces of surrounding cylinders. Pairs of tunnel elements are disposed within respective elongated voids and are each configured to releasably receive a corresponding forklift tong. Vertically-disposed pillars may be provided to increase the rigidity and load distribution of the system. Flaps may radiate from the pillars to minimize impact and abrasion between adjacent cylinders during shipment. Key system components may be inexpensively formed from recyclable, lightweight materials.