Plastic Pallet With Segmented Tunnel Receptacles
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Solution Overview
Problem
Existing plastic pallets for flexible bulk containers face issues with stability and protection against damage when stacking, as they can cause flexible bulk containers to bulge or expand, leading to potential rupture and impaired stability during forklift handling.
Innovation Solution
A plastic pallet design featuring four crosswise arranged tunnel-shaped receptacles with offset bottom and arch ribs, a base plate covering the crossing area with a crossing air gap, and arch ribs that reinforce the structure, along with flat supports for forklift tines and a reversible closure for bulk container emptying, enhances stability and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If plastic pallets with open-bottom tunnel-shaped receptacles are used for transporting flexible bulk containers, then the pallets can be nested to reduce storage space, but the flexible bulk containers can bulge or expand when stacked, leading to potential damage and impaired stability
Solution Approach 1:
The tunnel-shaped receptacles are segmented into multiple vertical sections using transverse partitions. These partitions divide the continuous tunnel space into discrete segments, preventing the flexible bulk container from bulging uniformly across the entire tunnel. Instead, the container is constrained in each segment, maintaining structural integrity while allowing nesting capability.
Solution Approach 2:
The invention introduces a vertical dimension of constraint within the tunnel receptacles through transverse partitions. Rather than relying solely on the horizontal tunnel shape, the vertical segmentation creates multiple constraint planes that prevent the container from expanding outward, solving the stability issue while preserving the nesting function.
2Ease of operation
If forklift tines enter the open-bottom tunnel-shaped receptacles to pick up the pallet, then the pallet can be easily handled, but the bulk goods container located under the pallet can be damaged
Solution Approach 1:
The transverse partitions are pre-installed within the tunnel receptacles before the forklift insertion process. This preliminary structural preparation creates safe zones that guide the forklift tines and prevent them from directly contacting the bulk goods container, thus preventing damage while maintaining ease of operation.
Solution Approach 2:
The transverse partitions act as intermediary structures between the forklift tines and the bulk goods container. They provide a physical barrier that intercepts the forklift insertion action, distributing the force and preventing direct contact with the container, thereby protecting it from damage.
3Productivity
If the tunnel-shaped receptacles are open at the bottom to allow nesting, then multiple pallets can be stacked efficiently, but the overall stability when stacking several loaded pallets is impaired
Solution Approach 1:
The transverse partitions segment the tunnel receptacles into multiple vertical sections, creating a more rigid internal structure. This segmentation prevents the tunnel walls from deforming under load, maintaining the pallet's structural integrity and stability even when multiple loaded pallets are stacked, while the open bottom design is preserved for nesting.
Data Source
Figure 1a
Figure 1b
Figure 2a
AI summary
A plastic pallet for receiving flexible bulk containers comprises at least one pair of tunnel-shaped receptacles for the fork tines of a forklift, with the tunnel-shaped receptacles connecting two opposite sides of the plastic pallet. Each tunnel-shaped receptacle has a tunnel bottom that is formed by bottom ribs spaced by bottom air gaps. Each tunnel-shaped receptacle also has a tunnel vault that is formed by vault ribs spaced by vault air gaps. In each of the tunnel-shaped receptacles, the bottom ribs and vault ribs are staggered and dimensioned in such a way that a bottom rib is arranged below a vault air gap and a vault rib is arranged above a bottom air gap.