Plastic Pallet Runner Segmentation for Replaceable Reinforcement
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Solution Overview
Problem
Plastic pallets are prone to damage from forklifts due to the thinness of their support feet, especially in smaller sizes, leading to increased risk of runner breakage and the need for costly reinforcement measures.
Innovation Solution
The runner surface is divided into separate elements with elongated reinforcing strips that can be easily replaced if damaged, held in place by stops and channels, allowing for quick disassembly and assembly, and connected to the cover plate via angled support members and fastening means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the support feet are made thinner to reduce material consumption, then the pallet weight and material usage decrease, but the risk of runner breakage increases
Solution Approach 1:
The runner is divided into multiple separate elements (first runner element, second runner element, third runner element) that can be independently replaced. This segmentation allows the use of thinner, less material-intensive components while maintaining overall system reliability through modular replaceability.
Solution Approach 2:
The invention enables easy replacement of damaged runner elements without replacing the entire pallet. Individual runner elements can be discarded when damaged and replaced with new ones, reducing material consumption over the pallet's lifetime while maintaining reliability.
2Strength
If reinforcement measures are added to strengthen the runners, then the runner strength increases, but the device complexity and production costs increase
Solution Approach 1:
By segmenting the runner into replaceable elements, the invention achieves strength through modular design rather than continuous reinforcement. Each element can be optimized for strength while the overall system complexity remains manageable due to the standardized modular approach.
Solution Approach 2:
The runner system transitions from a static, monolithic structure to a dynamic, replaceable modular system. This allows the pallet to adapt to damage conditions by replacing only affected elements, maintaining strength without requiring over-engineering of the entire structure.
3Reliability
If the entire runner is replaced when damaged, then the pallet reliability is restored, but the loss of time and material increases
Solution Approach 1:
The runner is segmented into independent replaceable elements, allowing only the damaged portion to be replaced rather than the entire runner. This significantly reduces replacement time and material waste while restoring pallet reliability.
Solution Approach 2:
The runner elements are designed with pre-integrated fastening means and connection features, allowing for quick replacement without complex assembly procedures. The preliminary design of these connection mechanisms enables rapid restoration of pallet reliability.
4Strength
If the support feet are made thicker to prevent damage, then the runner strength increases, but the material consumption and weight increase
Solution Approach 1:
The support feet and runners are segmented into replaceable elements that can be optimized for minimum necessary strength. This eliminates the need for excessive material thickness throughout the entire structure, reducing material consumption while maintaining adequate strength through modular replaceability.
Data Source
AI summary
A pallet includes a cover plate configured to accommodate articles, and at least two runners arranged underneath the cover plate, each runner including a runner standing surface, wherein each runner standing surface is subdivided centrally of each runner transversely thereto at a dividing plane and into at least two separate runner elements including a first runner element and a second runner element which, in the mounted position, combine to form the runner standing surface, and wherein each runner element includes an elongated reinforcing element which is held at a first end remote from the dividing plane by a stop in the first runner element and is held at a second end by the second runner element.