Support Layer Structure 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, particularly when packages overhang, leading to instability and product damage.
Innovation Solution
The use of a support layer with specific configurations, materials, and integration materials to stabilize cargo assemblages, ensuring efficient tessellation and compression, and incorporating features like bumpers and straps for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If packages are made larger to increase shipping efficiency, then shipping efficiency is improved, but pallet stability deteriorates when packages overhang more than 1.5-2 inches
Solution Approach 1:
A support layer is introduced as an intermediary component between the packages and the pallet. This support layer extends beyond the pallet perimeter to provide additional support for overhanging packages, enabling larger package sizes without compromising pallet stability. The support layer acts as a mediator that decouples the relationship between package size and pallet stability.
Solution Approach 2:
The support layer extends in the horizontal dimension beyond the pallet perimeter, creating an additional support zone. This dimensional extension allows packages to overhang further without causing instability, as the support layer provides the necessary structural reinforcement in the extended area.
2Device complexity
If standard size pallets are used to reduce cost and complexity, then cost and complexity are reduced, but adaptability to different product and package sizes deteriorates
Solution Approach 1:
The support layer is designed as a universal component that can be used with standard pallets to accommodate various product and package sizes. By adding this single multi-functional element, the same standard pallet can adapt to different shipping scenarios, maintaining versatility without requiring custom pallet designs.
Solution Approach 2:
The support layer is segmented into multiple components including integration materials and positioning elements, allowing it to be configured for different product sizes while maintaining compatibility with standard pallets. This segmentation enables flexibility and adaptability without complicating the overall pallet structure.
3Productivity
If packages overhang to increase shipping efficiency, then shipping efficiency is improved, but product damage increases due to insufficient support
Solution Approach 1:
The support layer serves as a protective intermediary between the packages and the pallet. It provides the necessary support for overhanging packages, preventing product damage while allowing packages to extend beyond the pallet perimeter for improved shipping efficiency.
Solution Approach 2:
The support layer is positioned beforehand to provide protective support for packages before they are loaded onto the pallet. This pre-positioned support structure prevents damage to overhanging packages during handling and transportation, cushioning them against potential harm.
4Stability of the object's composition
If a support layer is added to increase pallet stability and shipping efficiency, then stability and efficiency are improved, but device complexity increases
Solution Approach 1:
The support layer can be implemented as a flexible shell or thin film structure that provides necessary support without adding significant complexity. This thin-film approach maintains structural integrity while minimizing the added complexity compared to using a fully rigid support structure.
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.