Repairable Plastic Pallet With Angled Support Block Tabs
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Solution Overview
Problem
Plastic pallets are susceptible to damage from forklift or pallet jack tines, leading to durability and reparability issues, as they can separate when subjected to impact, and existing repairable pallets do not adequately address these concerns.
Innovation Solution
A plastic pallet design featuring a top and bottom deck with spaced support blocks, including angled tabs and grommets for enhanced grip and flexibility, allowing for 4-way entry by handling equipment and enabling easy replacement of damaged components for repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plastic pallets use a solid integrated structure, then strength and durability are improved, but reparability deteriorates as the entire pallet must be replaced when any component is damaged
Solution Approach 1:
The pallet is divided into separate modular components including support blocks with integrated forks, deck boards, and stringers that can be independently replaced. The support blocks serve as replaceable units that can be removed and replaced without damaging other pallet components, enabling partial repair rather than complete replacement.
2Ease of repair
If plastic pallets use a modular design with support blocks, then reparability is improved, but structural strength deteriorates due to additional connection points
Solution Approach 1:
The support blocks are designed to integrate multiple functions into single components: they provide structural support, incorporate fork entryways for handling equipment, and include attachment features for securing deck boards. This merging of functions reduces the number of separate connection points needed while maintaining structural integrity.
3Ease of manufacture
If plastic pallets are designed to be repairable with replaceable components, then cost-effectiveness is improved, but device complexity increases due to multiple parts
Solution Approach 1:
The support blocks are designed as universal components that serve multiple purposes: structural support, fork insertion points for 4-way entry handling, and attachment mechanisms for deck boards. This multi-functionality reduces the total number of unique parts needed while maintaining repairability and cost-effectiveness.
Data Source
AI summary
A pallet top deck, a bottom deck, and spaced apart support blocks coupled between the top and bottom decks. Each support block includes an inner wall surrounding an interior opening, an outer wall surrounding the inner wall, and a plurality of ribs extending between the inner and outer walls. First and second upper tabs extend outwards from upper surfaces of the inner wall, with each upper tab comprising an angled contact surface for engaging the top deck. The angled contact surfaces of the first and second upper tabs are oriented in a first direction. First and second lower tabs extend outwards from lower surfaces of the ribs, with each tab comprising an angled contact surface for engaging the bottom deck. The angled contact surfaces of the first and second lower tabs are oriented in a second direction that is orthogonal to the first direction.