Protective-Wall Pallets for Forklift Damage Prevention
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Solution Overview
Problem
Existing pallets do not adequately protect goods from mechanical damage during handling and storage, particularly from forklift tines, which can lead to hazards such as fire and environmental pollution from damaged lithium-ion batteries.
Innovation Solution
A pallet or load carrier with a protective wall projecting vertically upwards from the deck to prevent mechanical damage, combined with load-bearing points and a liquid-tight design to contain leaks, and optionally equipped with sensors for monitoring storage conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective device is placed on the pallet to prevent damage from forklift tines, then the protection against mechanical damage is improved, but the device complexity increases
Solution Approach 1:
The protective device is segmented into modular components: side walls forming a containment structure, protective elements positioned at critical locations, and sensor modules that can be independently installed. This segmentation allows the protection system to be built incrementally and maintained separately from the pallet structure itself.
Solution Approach 2:
The patent introduces sensors as intermediary devices that detect the position of forklift tines and trigger warning signals or automated responses before physical contact occurs. This intermediary detection layer prevents damage without requiring physical barriers that would complicate the pallet structure.
2Ease of operation
If the forklift truck's forks are set too high, then the forks can reach the products on the pallet, but this causes mechanical damage to the products
Solution Approach 1:
The protective device incorporates sensors that provide real-time feedback on the vertical position of forklift forks relative to the pallet and products. When forks approach a dangerous height, the system generates warnings to the operator, creating a feedback loop that prevents damage while maintaining operational flexibility.
Solution Approach 2:
The system performs preliminary detection and warning actions before actual contact between forks and products can occur. By detecting fork position in advance and alerting the operator, the system prevents damage proactively rather than reactively.
3Reliability
If a protective sleeve is placed on the pallet to prevent goods from sliding off or being damaged, then the protection against mechanical damage is improved, but the device complexity increases
Solution Approach 1:
The protective functions are merged into a single integrated device structure: side walls provide both containment to prevent sliding and protection against impact, while sensors and warning systems are integrated into the same structure. This consolidation reduces the number of separate components compared to traditional protective sleeves.
4Volume of stationary object
If the volume of the pallet is reduced by nesting when unloaded, then the storage efficiency is improved, but the protection capability is reduced
Solution Approach 1:
The protective device incorporates dynamic elements such as collapsible side walls or removable protective elements that can be adjusted between transport and storage modes. During transport, the structure maintains full protective capability; during storage, it can be collapsed or reconfigured to enable nesting, providing dynamic adaptability to different operational requirements.
Data Source
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AI summary
Pallet or load carrier (1) comprising a deck (3) with a base and at least two parallel longitudinal beams (5), wherein the longitudinal beams (5) are arranged below the deck (3) and connected to the deck (3), and wherein a protective wall (7) is provided on at least one side of the deck (3) which projects vertically beyond the deck (3). The pallet or load carrier makes it possible to store hazardous goods, such as lithium-ion batteries, and to protect them from mechanical damage, such as from the tines of a lifting device or a forklift.