Plastic Pallet Runner System for Load Bearing and Nesting
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Solution Overview
Problem
Current pallet designs are heavy, prone to sag, and lack durability, making them inefficient for bearing dynamic loads of 2000 pounds or more, and they do not easily nest or store, posing challenges in space management and safety.
Innovation Solution
A lightweight, molded pallet with a runner system featuring a 'V/U/flattened V' profile and Z-girt construction, allowing for nesting and stacking, and made from materials like plastic or composite materials that are resistant to sag and microbial invasion, enabling easy transport and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional wood or metal pallets are used to bear dynamic loads of 2000 pounds or more, then load-bearing capability is improved, but weight increases and durability decreases due to swelling and contracting
Solution Approach 1:
The patent changes the material parameter from traditional wood or metal to high-density polyethylene plastic, which maintains load-bearing capability for 2000+ pounds while reducing weight and eliminating swelling/contracting issues. The plastic material's inherent properties provide dimensional stability and corrosion resistance while being lighter than wood or metal alternatives.
Solution Approach 2:
The patent employs composite construction by integrating a deck portion with a runner system into a unitary molded structure. This composite design combines the load-bearing deck with the nested runner storage feature, creating a multi-functional pallet that maintains strength while reducing overall weight through optimized material distribution.
2Strength
If pallets are made heavier to accommodate intended uses and bear adequate weight, then load-bearing capability is improved, but ease of storage and transport worsens
Solution Approach 1:
The patent incorporates a nested runner system within the pallet structure, where runners can be stored inside the pallet when not in use. This nesting feature allows the pallet to maintain its load-bearing capability while significantly improving storage efficiency and ease of handling by eliminating the need for separate runner storage.
3Ease of manufacture
If wood pallets are used, then ease of manufacture is improved, but durability worsens due to susceptibility to bacteria, mold, fungus and swelling
Solution Approach 1:
The patent changes the material parameter from wood to high-density polyethylene plastic, which provides superior durability by being immune to bacteria, mold, and fungus. The plastic material also eliminates swelling and contracting issues while maintaining manufacturing efficiency through molded unitary construction.
4Strength
If plastic pallets are designed to bear adequate weight and resist sag, then load-bearing capability is improved, but weight increases requiring more materials
Solution Approach 1:
The patent applies local quality by concentrating material only where structurally necessary - the deck portion has sufficient thickness for load-bearing, while the runner system uses thinner walls since it stores empty. This localized material distribution allows the pallet to resist sag and bear 2000+ pounds without requiring excessive material throughout the entire structure.
Solution Approach 2:
The patent utilizes thin-walled hollow runner construction that provides structural support through geometric shape rather than material thickness. The runners are formed with thin plastic walls that are sufficient for their nesting and storage function, reducing overall pallet weight while the deck portion maintains adequate thickness for load-bearing requirements.
Data Source
AI summary
A pallet having a unique runner system where each runner opens into the upper deck of the pallet or opens away from the upper deck, and each runner is formed of a construction of z girts back to back resulting in a flattened “V” or “U”. Each runner may optionally include an elongated notch on its bottom surface or an opening to allow forklift tines to slide into for easy transport of the pallet. The pallet may also include cross runners of similar construction for additional strength. The pallet's construction allows the pallet to be made of plastic material, perhaps molded, providing lighter weight and longer durability than its wooden cousins.