Configurable Shock Pallet with Variable Density Foam
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Solution Overview
Problem
Current shock pallets for shipping information handling systems (IHSes) are inadequate as they fail to provide optimal damping for a wide range of rack weights, leading to equipment damage and increased manufacturing complexity due to a fixed design that is either too rigid for lighter loads or collapses under heavier loads.
Innovation Solution
A configurable shock pallet system with removable dampening inserts of varying densities, allowing for customization based on the weight profile of the IHS, which can be easily assembled and disassembled to accommodate different weight ranges and distributions, including off-center loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single shock pallet with dense foam is designed for a specific rack weight (2800 lbs), then the shock pallet provides adequate dampening for that specific weight range, but it becomes too rigid for lighter loads (less than 2300 lbs.) and collapses for heavier loads (more than 3300 lbs.)
Solution Approach 1:
The shock pallet is divided into multiple functional layers with different foam densities (e.g., 20 lbs/ft³, 30 lbs/ft³, 40 lbs/ft³). Each layer can be independently selected and stacked to match the weight range of the cargo, allowing the system to adapt to various load conditions while maintaining reliable dampening performance.
Solution Approach 2:
The shock pallet configuration is made dynamic by allowing the selection and arrangement of foam layers with different densities based on the actual cargo weight. This transforms a static, single-density design into a flexible system that can be optimized for each shipping scenario, preventing both excessive rigidity and collapse.
2Reliability
If multiple shock pallets are designed for different rack weights, then each shock pallet can be optimized for its specific weight range, but manufacturing and staging complexity increases significantly
Solution Approach 1:
A single universal shock pallet design incorporates multiple foam density options that can be combined in different configurations. This multi-functional approach allows one pallet design to serve multiple weight ranges, eliminating the need for separate pallet designs for different weights and reducing manufacturing and staging complexity.
Solution Approach 2:
Instead of creating multiple pallet designs, the solution changes the density parameter of the foam material within a single pallet design. By offering a selection of foam densities (20, 30, 40 lbs/ft³) that can be stacked in various combinations, the system achieves weight-specific optimization without increasing overall device complexity.
3Strength
If dense foam is used to increase dampening capability, then the shock pallet can handle heavier loads, but the foam collapses under excessive weight (more than 3300 lbs.) and cannot provide adequate dampening
Solution Approach 1:
Different regions or layers of the shock pallet are assigned different foam densities based on the local support requirements. Heavier load areas use higher density foam (40 lbs/ft³) for structural support, while lighter areas use lower density foam (20 lbs/ft³) for optimal dampening, preventing both collapse and excessive rigidity.
Solution Approach 2:
The shock pallet uses a composite structure combining multiple foam densities in a single assembly. This composite approach allows the pallet to simultaneously provide structural strength from high-density foam and dampening performance from low-density foam, preventing collapse while maintaining effective shock absorption across a wider weight range.
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
The configurable shock pallet system reduces inventory complexity, minimizes equipment damage by providing tailored damping for each load, and allows for efficient assembly and refreshment of shock pallets, ensuring effective protection during transportation.
Implementation Method 1
A configurable shock pallet system with removable dampening inserts of varying densities, allowing for customization based on the weight profile of the IHS
Implementation Method 2
Each dampening insert has a density that is selected from more than one available density
Data Source
AI summary
A configurable shock pallet accommodates different types of rack-mounted information handling systems (IHSes) having different weight profiles. A bottom structure has a pair of parallel apertures to receive forklift tines. A top deck receives a rack-mounted IHS of a selected weight profile for shipping. A horizontal array of pad locations is designated between the bottom structure and the top deck. Dampening inserts are assigned to respective pad locations of the horizontal array from dampening inserts of different densities. Attaching components secure the top deck to the bottom structure, separated by the dampening inserts to provide appropriate shock protection for the weight and weight distribution of the IHS. A shock pallet configuring system can receive a weight profile and indicate on an output interface the assigned pad configuration to manually or automatically assemble the configured shock pallet.