Resin Pallet Flex Assembly Interlock Mechanism
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Solution Overview
Problem
Molded resin pallets face challenges in competing with wooden pallets due to weak interconnections, high manufacturing costs, and difficulties in disassembly for cleaning or repair, with existing solutions like welding and fasteners proving unsatisfactory.
Innovation Solution
The flex assembly method securely interlocks a pallet deck and base using inflexible male and female locking features connected by flexible spans that can be bent to engage and disengage, providing a strong and robust interlock without fasteners or glue, allowing for automatic assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional interconnection methods (welding, fasteners, glue) are used to join pallet deck and base, then structural strength is improved, but ease of disassembly deteriorates and manufacturing cost increases
Solution Approach 1:
The interconnection system is divided into separate male and female locking features that can engage and disengage independently. The deck and base are segmented into modular components with complementary interlocking elements, allowing the pallet to be assembled and disassembled without destructive forces while maintaining strong connection during use.
Solution Approach 2:
The interconnection system transitions from static permanent joints (welding, glue) to dynamic reversible joints. The male and female locking features are designed to be engaged during assembly and disengaged during disassembly, providing both strength during operation and ease of separation when needed, adapting the connection state based on operational requirements.
2Strength
If traditional interconnection methods (welding, fasteners, glue) are used to join pallet deck and base, then structural strength is improved, but manufacturing cost increases
Solution Approach 1:
The male and female locking features are integrated directly into the molded structures of the deck and base respectively, combining the interconnection function with the structural components themselves. This eliminates the need for separate fasteners, welds, or adhesive applications, reducing part count and manufacturing steps while maintaining strong interconnection.
Solution Approach 2:
The interconnection system is designed to be self-assemblying through the engagement of male and female locking features during the molding process or subsequent assembly. The结构设计 allows the components to lock together automatically without requiring external fasteners, welding equipment, or adhesive application, thereby simplifying manufacturing and reducing costs.
3Adaptability or versatility
If molded resin pallets use separate deck and base with traditional interconnections, then manufacturing flexibility is improved, but durability deteriorates due to weak interconnections
Solution Approach 1:
The interconnection system utilizes complementary male and female locking features made from the same or compatible resin materials, creating a composite interlocking structure that combines the advantages of molded resin flexibility with the strength of positive mechanical engagement. This composite approach maintains manufacturing flexibility while significantly improving durability compared to traditional weak interconnections.
Data Source
AI summary
Resin pallets having a deck and a base, where the deck and base are joined by an interlock, which is optionally reversible, are described. Methods of making such pallets by assembling the pallets by interlocking parts to form the pallets, in an optionally reversible method, are also described.