Interlocking Ring-Wall Floor Plate for High Load Capacity
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Solution Overview
Problem
Existing floor plates, particularly those made of plastic and wood, face issues such as damage from forklift collisions, limited load capacity, moisture absorption, and high maintenance costs due to mold growth, leading to inadequate structural strength and durability.
Innovation Solution
A support unit comprising two metal plates with hollow cylindrical ring walls that interlock to form a stable structure, providing high structural strength and bearing capacity while minimizing weight, and a manufacturing method that involves machining and stamping to create these interlocking features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plastic floor plates are used, then they are easy to manufacture and have low cost, but they are easily damaged by forklift collision and have limited load capacities
Solution Approach 1:
The floor plate is divided into multiple modular support units, each consisting of a first plate, second plate, and interlocking ring walls. This segmentation allows each module to be manufactured separately with simpler processes while achieving high overall strength through the modular assembly, resolving the contradiction between manufacturing ease and structural strength.
Solution Approach 2:
The support unit combines metal materials (steel or aluminum alloys) with optimized structural design, creating a composite structure that integrates the strength of metal with the efficiency of the interlocking ring wall design. This achieves high load capacity while maintaining manufacturing feasibility through standard metal forming processes.
2Reliability
If wooden floor plates are used, then they are easy to manufacture and have low cost, but they are easy to absorb moisture and become moldy, leading to high use cost
Solution Approach 1:
The invention changes the material parameter from organic materials (wood, plastic) to metal materials with superior resistance to moisture and mold. The metal plates and ring walls are manufactured with controlled dimensions and interlocking features, achieving durability through material selection rather than complex protective treatments, thus resolving the contradiction between reliability and manufacturing simplicity.
3Strength
If solid metal plates are used to increase strength, then bearing capacity improves, but weight increases significantly
Solution Approach 1:
Instead of using solid metal plates throughout, the invention applies metal material locally only where structurally necessary - in the interlocking ring walls and connecting portions. The spaces between ring walls and within modules are left as cavities, providing local strength enhancement while minimizing overall weight, thus resolving the contradiction between structural strength and weight.
Solution Approach 2:
The support unit incorporates a porous or hollow structure through the cavity formations between ring walls and within modular sections. This creates a lightweight metal structure with high strength-to-weight ratio, achieving bearing capacity without the weight penalty of solid plates, effectively resolving the contradiction between strength and weight.
4Strength
If ring walls are added to form support structures, then structural strength and bearing capacity improve, but device complexity increases
Solution Approach 1:
The invention merges the functions of support, connection, and structural reinforcement into a single integrated ring wall component. The ring walls simultaneously provide structural support, connect the first and second plates, and reinforce the modular sections, reducing the number of separate components needed and simplifying the overall device while maintaining high structural strength.
Solution Approach 2:
The ring walls are designed as multi-functional elements that perform multiple roles: providing structural support, enabling interlocking between plates, creating modular sections, and facilitating assembly. This multi-functionality reduces the need for additional specialized components, thereby reducing device complexity while achieving high structural strength.
Data Source
AI summary
Disclosed are a support unit and a floor plate. The support unit includes a first plate and a second plate which are spaced apart from each other, one end of the first plate is provided with a plurality of first ring walls at intervals, one end of second plate facing the first plate is provided with a plurality of second ring walls at intervals, the plurality of second ring walls are arranged corresponding to the plurality of first ring walls, each of the second ring walls is sleeved outside and matched with a respective one of the first ring walls to form a support structure that supports the first plate and the second plate.