Support Layer Assembly for Stable Overhanging Pallet Loads
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Solution Overview
Problem
Manufacturers face challenges in maximizing pallet stability and shipping efficiency while accommodating a broad range of product and package sizes using standard size pallets, leading to issues such as product damage and instability, especially when packages overhang or when the first cargo assemblage lacks stability.
Innovation Solution
The use of a support layer with specific configurations, materials, and integration materials to enhance stability and efficiency, including features like H-shaped, Z-shaped, C-shaped, and I-shaped panel components, and integration materials extending between layers to apply compressive and stabilizing forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If packages are made larger or allowed to overhang the pallet, then shipping efficiency and product variety increase, but pallet stability deteriorates and product damage occurs
Solution Approach 1:
A support layer is introduced as an intermediary element between the packages and the pallet. This support layer extends beyond the pallet edges to provide additional support for overhanging packages, enabling larger package sizes and better shipping efficiency while maintaining pallet stability. The support layer acts as a mediator that allows packages to overhang without compromising the structural integrity of the pallet load.
2Ease of manufacture
If standard size pallets are used to reduce cost and complexity, then manufacturing and operational simplicity improve, but the ability to accommodate a broad range of product sizes is limited
Solution Approach 1:
The support layer is divided into multiple panel components (H-shaped, Z-shaped, C-shaped, and I-shaped panels) that can be selectively assembled. This segmentation allows the support layer to be configured in different patterns to accommodate various package sizes and shipping requirements while still using standard pallets, thus maintaining ease of manufacture while improving adaptability.
3Stability of the object's composition
If integration materials are added to extend between layers and apply compressive forces, then cargo assemblage stability improves, but device complexity increases
Solution Approach 1:
The integration materials (such as straps or bands) are combined with the support layer structure to form an integrated stabilization system. The integration materials extend between layers and apply compressive forces while being attached to the support layer, merging multiple functions (support, compression, and layer integration) into a unified system that improves stability without proportionally increasing complexity.
Data Source
AI summary
Cargo assemblages including a pallet, a load of packages arranged in one or more layers, and a support layer, in which the support layer is sized and positioned within the cargo assemblage to support and/or stabilize the cargo, thereby providing improved pallet efficiency, improved shipping efficiency, and/or improved stability.