Plastic Load Carrier Frame with Integrated Protective Profile
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Solution Overview
Problem
Existing large load carriers made of plastic suffer damage when stacked and moved by forklifts, as the tines often penetrate the bottom, causing destruction due to the lack of effective protection in the lower frame area.
Innovation Solution
A plastic protective profile with a plug-in strip is integrated into the frame, forming a unit that prevents forklift tines from penetrating, and is produced by injection molding for cost-effectiveness, with optional metal reinforcement for added stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal profile bar is used to protect the lower frame area, then the protective effect is improved, but the cost and weight increase
Solution Approach 1:
The patent replaces expensive metal profile bars with a plastic protective profile that is integrated into the container structure. The plastic profile is designed to be cost-effective while providing sufficient protection for the intended service life of the container, eliminating the need for costly metal components.
Solution Approach 2:
The protective profile is formed as a composite structure combining the plastic container wall with an integrally molded protective element. This composite approach allows the plastic material to provide both structural and protective functions, replacing the need for separate metal protection components.
2Ease of operation
If the U-profile is open at the front for forklift engagement, then the ease of operation is improved, but the protective reliability deteriorates as tines may miss the profile
Solution Approach 1:
The protective profile extends vertically along the lower frame area, creating a three-dimensional barrier that covers both the front opening area and the rear container floor area. This vertical extension ensures that forklift tines engage the profile from the front while the vertical coverage prevents penetration to the container floor.
Solution Approach 2:
The protective profile is designed as a separate integrated component that divides the lower frame area into a protected zone and an engagement zone. The profile structure separates the function of forklift engagement (front portion) from the function of protection (vertical and rear portions), allowing both functions to be optimized independently.
3Reliability
If the protective profile bridges the area between the profile and container floor, then the protective reliability is improved, but the device complexity increases
Solution Approach 1:
The protective profile is integrally molded as a single piece with the container structure, merging the protective function with the existing frame structure. This integration eliminates the need for separate components, fasteners, or assembly steps, reducing structural complexity while maintaining comprehensive protection.
Data Source
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AI summary
The invention relates to a large load carrier (1) consisting of plastic, comprising a base (2) that accommodates the loads, support feet (13) being arranged at least at the corner regions of the underside of said base, and the base being surrounded by a double-walled frame (3), wherein the inner wall and the outer wall (4, 5) of the frame (3) are interconnected by means of vertical webs (6) and strip-shaped protective profiled elements each being provided between two respective support feet (13) in the lower frame area, wherein the rear of the protective profiled element (8) is supported against the inner wall (4) of the frame (3). The large load carrier is characterized in that the protective profiled element (8) is a plastic part, on the one longitudinal edge of which an insertion strip (15) for inserting into the gap (7) between the inner wall and the outer wall (4, 5) of the frame (3) is formed, and forms a unit with the profiled element (8).