Configurable Rackable Pallet Assembly for Dual Deck Heights
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Solution Overview
Problem
Existing plastic pallets require separate molds for producing different heights, leading to inefficiencies in production and storage efficiency due to the need for multiple pallet types.
Innovation Solution
A pallet design that allows assembly in two configurations, one with increased height and the other with decreased height, using a single set of molds, achieved by rotating components and employing snap-fit connections for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate molds are used for producing pallets with different heights, then pallets can accommodate different material handling equipment requirements, but production complexity and cost increase due to multiple mold sets
Solution Approach 1:
The column is divided into an upper column portion and a lower column portion that can be assembled in different orientations. The upper column portion includes an upper support surface while the lower column portion includes a lower support surface. By assembling these segments in different configurations (upright or inverted), the pallet can achieve different heights to accommodate various material handling equipment requirements without needing separate molds.
Solution Approach 2:
The same mold set is used to produce both the upper and lower column portions, which can be assembled in multiple configurations to create pallets of different heights. This universal mold design allows a single mold set to serve multiple functions: producing components for both high-height and low-height pallet configurations, thereby eliminating the need for separate dedicated molds for each pallet type.
2Productivity
If pallet height is reduced to improve storage efficiency, then storage and shipping efficiency improve, but the pallet may not accommodate the material handling equipment being used
Solution Approach 1:
The pallet design allows dynamic reconfiguration of the column assembly orientation. The upper column portion can be assembled upright or inverted relative to the lower column portion, enabling the pallet height to be adjusted based on the specific material handling equipment requirements. This dynamic adaptability ensures that storage efficiency is optimized by selecting the appropriate height configuration for each application scenario.
3Adaptability or versatility
If two sets of molds are used to produce pallets with different heights, then both high and low height pallets can be produced, but production time and resource consumption increase
Solution Approach 1:
A single mold set is designed to produce both upper and lower column portions that can be assembled in different configurations. This universal mold eliminates the need for maintaining and operating two separate mold sets, thereby reducing production time, lowering resource consumption, and improving overall production efficiency while still enabling the manufacture of pallets with different heights.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables production of pallets with different heights using a single mold set, enhancing production efficiency and storage flexibility.
Implementation Method 1
a plurality of snap tabs extending inwardly from the peripheral wall and a plurality of snap-receiving features formed on the interior surface of the other component, wherein the snap tabs and the snap-receiving features engage one another
Data Source
AI summary
A pallet includes an upper structure and a lower structure. The upper structure includes an upper deck and a plurality of upper column portions projecting downward from the upper deck. The lower structure includes a plurality of lower column portions. The upper column portions and the lower column portions are configured such that the upper deck is configured at first height when the upper structure is secured to the lower structure in a first orientation and the upper deck is configured at a second height when the upper structure is secured to the lower structure at a second orientation. Optionally, the upper deck of the pallet includes a plurality of perimeter regions into which a desired one of a plurality of inserts can be secured to produce pallets with different perimeter options.