A-Frame Pallet Assembly for Upright Building Kit Staging
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Solution Overview
Problem
Manufacturers face challenges in transporting building kits due to large and cumbersome materials, leading to excessive shipping costs and labor-intensive unloading processes.
Innovation Solution
The use of pallet assemblies with A-shaped support frames that maintain building materials in an upright position, allowing for compact packaging and efficient loading/unloading, while ensuring the overall height is under a predetermined limit to avoid additional shipping charges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If building materials are transported in traditional flat packaging, then shipping space utilization is poor and shipping costs increase, but standing the materials upright improves space utilization and reduces shipping costs, yet makes loading and unloading more difficult
Solution Approach 1:
The patent transitions from traditional flat horizontal packaging to a three-dimensional upright stacking configuration. The A-frames and stacking pins enable materials to be arranged vertically in multiple layers,充分利用 the height dimension of the shipping container, thereby significantly improving space utilization while maintaining ease of handling through the specialized structural components.
Solution Approach 2:
The A-frames serve as intermediary structures that facilitate both upright positioning and easy handling. These A-frames with stacking pins act as mediators between the building materials and the shipping container, enabling vertical stacking while providing grip points for loading and unloading operations, thus resolving the contradiction between space utilization and operational ease.
2Quantity of substance
If the pallet assembly height is increased to accommodate longer materials, then more materials can be shipped in one freight, but additional shipping charges and fees are incurred
Solution Approach 1:
Instead of increasing height to accommodate more materials, the patent utilizes horizontal expansion through multiple A-frame configurations and efficient lateral arrangement. The stacking pins and A-frame design enable materials to be organized in a three-dimensional grid pattern that maximizes container volume without exceeding height restrictions, thereby increasing quantity shipped while avoiding additional charges.
Solution Approach 2:
The patent optimizes the dimensional parameters of the pallet assembly, specifically maintaining height within the 96-inch threshold while adjusting length and width configurations. By changing the arrangement parameters rather than simply increasing height, the system accommodates more materials within the same height constraint, avoiding excessive shipping charges while maximizing quantity.
3Loss of energy
If building materials are shipped in multiple freights, then shipping costs increase, but consolidating all materials in one freight reduces shipping costs, yet makes unloading and handling more labor-intensive
Solution Approach 1:
The patent segments the consolidated freight into organized sections using multiple A-frames and stacking pin configurations. This segmentation allows materials to be grouped by type or installation sequence, enabling more efficient unloading operations even when all materials are shipped in one freight. The segmented structure reduces labor intensity by facilitating systematic access to different material groups without requiring complete unloading and reorganization.
Solution Approach 2:
The A-frames and stacking pins perform preliminary organization and positioning of materials during loading. This preliminary action ensures that materials are pre-arranged in an optimal sequence and configuration before shipping, significantly reducing the labor required during unloading and handling operations, thus enabling consolidated shipping without proportionally increasing labor intensity.
4Productivity
If building materials are delivered in traditional packaging, then customers receive all materials at once, but customers need additional assistance and time to unload and organize the cumbersome freight
Solution Approach 1:
The pallet assembly performs preliminary organization of materials during the packaging and shipping process. Materials are pre-positioned in a logical sequence using A-frames and stacking pins that correspond to installation steps. This preliminary action enables customers to systematically unload and organize materials with minimal assistance and time, significantly improving delivery efficiency while reducing the time loss associated with unloading and organization.
Solution Approach 2:
The standardized A-frame and stacking pin design enables customers to independently handle and organize materials without requiring professional assistance. The self-explanatory structure and ergonomic design allow DIY customers to efficiently unload and arrange materials themselves, transforming a task that previously required help into a manageable self-service operation, thus improving delivery efficiency while minimizing time loss.
Data Source
AI summary
A pallet assembly and method of use for carrying a building kit. The pallet assembly includes a base, an A-frame operably engaged with the base, a first upright support of the A-frame operably engaged with the base at a first position defined at a first angle measured relative to the base, and a second upright support of the A-frame operably engaged with the base at a second position opposite to the first position and defined at a second angle measured relative to the base. The pallet assembly may also include a pair of cleats operably engaged with the base and spaced apart from the A-frame.