Single Sheet Pallet with Interconnected Legs for Roller Conveyor Compatibility
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Solution Overview
Problem
Single sheet plastic pallets are too flexible and incompatible with roller conveyors, while double sheet pallets are heavier and more expensive due to increased plastic material and complex fabrication requirements.
Innovation Solution
A single sheet pallet design with a peripheral lip and interconnected legs that provide a continuous floor plane, allowing for four-way forklift entry, nestability, and compatibility with roller conveyors, using vacuum thermoforming or injection molding techniques, which reduces manufacturing complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If single sheet pallet design is used, then weight is reduced and manufacturing cost is lowered, but flexibility is excessive and compatibility with roller conveyors is poor
Solution Approach 1:
The single sheet is segmented into multiple functional zones including leg structures, connector regions, and a continuous floor plane area. The sheet is divided into nine leg positions arranged in three rows of three, with interconnected structures between adjacent legs that create a segmented yet integrated design providing both weight reduction and structural reliability
Solution Approach 2:
The invention transitions from a simple flat single sheet to a three-dimensional structure by forming legs that extend downward and connectors that interlink these legs. This dimensional transformation creates a continuous floor plane at a lower elevation while maintaining the lightweight single sheet advantage, solving the contradiction between weight reduction and roller conveyor compatibility
2Device complexity
If single sheet pallet design is used, then manufacturing complexity is reduced, but structural rigidity is insufficient
Solution Approach 1:
The corners of the peripheral lip are radiussed rather than sharp, and the leg structures incorporate curved transitions. This use of curvature distributes stress more effectively throughout the single sheet structure, enhancing rigidity without requiring complex multi-sheet assemblies or metal reinforcements
Solution Approach 2:
The invention utilizes a composite structure within the single sheet by integrating different functional regions with distinct geometries - legs for support, connectors for linkage, and a peripheral lip for containment. This internal composite design provides enhanced structural rigidity while maintaining manufacturing simplicity through single-sheet fabrication
3Strength
If double sheet pallet design is used, then structural rigidity is improved, but weight increases and manufacturing cost increases
Solution Approach 1:
The invention merges the functions of two separate sheets into a single integrated sheet structure. The single sheet simultaneously provides the upper surface, leg structures, connectors, and peripheral lip functions that would traditionally require two separate sheets joined together. This consolidation reduces weight and manufacturing complexity while maintaining structural rigidity through intelligent geometric design
Solution Approach 2:
The single sheet is designed to perform multiple functions that would traditionally require separate components: it provides the load-bearing surface, structural legs, interconnecting elements, and peripheral containment all in one piece. This multi-functionality eliminates the need for a second sheet while maintaining the structural advantages of twin-sheet designs
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 design achieves rigidity without metal reinforcement, supports high loads, and minimizes deflection, while being cost-effective and compatible with stretch wrapping and roller conveyors, offering a lightweight alternative to double sheet pallets.
Implementation Method 1
a peripheral lip around the upper boundary of the pallet which is greater in width and length than the underlying but integral base structure... allows for the use of a plastic or fabric load cover which is stretched around the lip and then relaxed under the under surface of the radiussed peripheral lip to snugly hold the load to the pallet
Implementation Method 2
adjacent legs are all interconnected by structure which has a bottom surface on the same floor plane as each of the nine regular legs, these connectors having geometries that substantially increase the amount of surface area available on the floor plane and provide continuity which allows the pallet to roll over a roller conveyor
Data Source
AI summary
A single sheet unitary molded plastic pallet has nine open top molded plastic leg structures extending to a common floor plane wherein the leg structures are arranged in three columns and three rows and include a center leg structure. The pallet also has connector structures arranged between the leg structures and having corner ribs extending therefrom to the leg structures so as to provide a floor plane which is substantially continuous in all directions, and a load plane which is substantially continuous in all directions. The side surfaces of the connector structures having opening for forklift tangs. The pallet has a continuous peripheral lip which can accept an elasticized load cover.