Toggle Latch Pallet Modules for Robust Nesting

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Solution Overview

Problem

Existing pallet modules are insufficiently robust, prone to disconnection during handling and transport, and lack flexibility in size and configuration, leading to inefficiencies in shipment and warehousing, with conventional wooden pallets being cost-inefficient and environmentally unsustainable.

Innovation Solution

A pallet module design featuring a quadrilateral main structural body with lateral flanges and grooves for nesting, toggle latch components for secure interlocking, and a releasable foot structure, allowing for easy assembly and disassembly, and enabling the creation of various pallet assemblies of different sizes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conventional interlocking systems are used to connect pallet modules, then assembly is simplified, but the connection becomes insufficiently robust and prone to disconnection during handling and transport

Engineering Contradiction:

Improveassembly simplicityVSAvoidconnection robustness

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The toggle latch components are designed to transition between open and closed positions, allowing easy assembly when open and providing robust connection when closed. The dynamic mechanism enables the user to simply pull the latch to open it for assembly, then push it to close it for secure locking, resolving the contradiction between ease of assembly and connection robustness.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The toggle latch components are extracted as separate, removable elements from the pallet module structure. This allows the interlocking system to be easily assembled and disassembled by simply engaging or disengaging the latch components, while still providing robust connection when engaged, thus resolving the contradiction between assembly simplicity and connection reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of manufacture

If fixed-size pallet modules are used, then manufacturing is simplified, but flexibility in creating various pallet assemblies is reduced

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidpallet assembly flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The pallet system is segmented into multiple standardized modules of different sizes (small, medium, large) that can be combined in various configurations. Each module maintains simplified manufacturing through standardized designs, while the segmentation enables flexible assembly of different pallet sizes and configurations to meet diverse shipping and storage needs, resolving the contradiction between manufacturing simplicity and assembly flexibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The pallet modules are designed with universal features including standardized toggle latch components, nesting capabilities, and compatible interlocking mechanisms that work across all module sizes. This universality allows simple standardized manufacturing while enabling versatile combination of modules to create various pallet assemblies for different applications.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If integral foot structures are used on pallet modules, then structural integrity is improved, but nesting and space utilization are reduced

Engineering Contradiction:

Improvestructural integrityVSAvoidnesting efficiency

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The pallet modules are designed with nesting capabilities where smaller modules can be placed within larger modules when not in use. The foot structures are configured to allow this nesting arrangement while maintaining structural integrity during load-bearing operations, resolving the contradiction between structural strength and nesting efficiency for space optimization.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS12071273B2Pallet module, assortment of pallet modules, and pallet assembly built of the same

Publication Date: 2024.08.27 PONERA GRP SAGL

AI summary

A pallet module configured to allow formation of a nested pallet assembly of at least two similar pallet modules, including a main structural body having a generally quadrilateral peripheral border with first to fourth lateral sides, first and second lateral flanges extending outwardly from the peripheral border along the first and second lateral sides and configured to cooperate with first and second lateral grooves extending inwardly from the peripheral border along the third and fourth lateral sides of another similar pallet module to form the nested pallet assembly, a foot structure disposed on a lower side of the main structural body, and first and second toggle latch components arranged in the vicinity of the first and second lateral sides, respectively, configured to cooperate and releasably interlock with third and fourth toggle latch components arranged in the vicinity of the third and fourth lateral sides, respectively, of another similar pallet module.