Unitary Void Filling Apparatus for Pallet Load Stabilization
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Solution Overview
Problem
Existing solutions fail to effectively stabilize loads with underhang gaps between pallets, particularly when these gaps are not uniform, and cannot efficiently maintain position during insertion and removal, leading to inadequate protection from end-to-end forces and dust accumulation.
Innovation Solution
A frame structure with variable dimensions and attachable void fillers, constructed from corrugated paperboard, that can be positioned in different orientations to fill lengthwise voids between pallets, providing protection from end-to-end forces and acting as a dust cover, with optional corrugated covers and honeycomb or paper-based void fillers to secure the load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dunnage materials are stuffed between loads on adjacent pallets, then voids are filled, but the materials cannot stay in the proper protective position and cannot be implemented efficiently
Solution Approach 1:
The void filling system is segmented into a frame structure with separate void filler components that can be independently positioned and secured. The frame divides into side members that can be inserted first, followed by void fillers that fit into designated spaces, allowing systematic placement that ensures position stability while maintaining operational efficiency.
Solution Approach 2:
The frame structure acts as an intermediary between the void fillers and the cargo, providing a stable framework that holds the void fillers in proper protective positions. The frame members serve as mediators that secure the flexible void filler materials, preventing them from shifting while allowing efficient insertion and removal of the entire assembly.
2Reliability
If adhesive strips are used to hold cargo together, then cargo is secured, but the solution requires cargo to be in close proximity and does not contemplate underhang space
Solution Approach 1:
The frame structure is designed with adjustable and reversible side members that can adapt to dynamic variations in underhang dimensions. The side members can be repositioned along the frame and the entire frame can be reversed to accommodate different underhang configurations, providing versatility for securing cargo with non-uniform gaps that adhesive strips cannot address.
Solution Approach 2:
The system allows for parameter changes in the frame dimensions and side member positions to accommodate varying underhang spaces. By adjusting the spacing and orientation of frame components, the structure can adapt to different cargo configurations and underhang measurements, making it versatile for various securing scenarios beyond what fixed adhesive strips can provide.
3Adaptability or versatility
If a frame structure with variable dimensions is used, then different pallet sizes and underhangs are accommodated, but device complexity increases
Solution Approach 1:
The frame structure is designed as a universal, multi-functional device that can accommodate various pallet sizes and underhang configurations through standardized components. The side members can be repositioned and the frame can be reversed, allowing a single frame design to serve multiple cargo securing needs, thereby reducing overall system complexity while maintaining high adaptability.
Solution Approach 2:
The frame structure employs a nested design where side members can be positioned within or along the frame members, and void fillers are nested within the frame structure. This nesting approach allows for compact storage and easy assembly/disassembly, reducing the operational complexity despite the variable dimensions needed for different pallet sizes.
Data Source
AI summary
A unitary void filling apparatus for use as a lengthwise void spacer which is capable of preventing movement of a load disposed on a pallet, protecting the load from end-to-end forces, and acting as a dust cover. The apparatus consists of a frame folded to make a central area, which fits on top of the load, and two vertical sides, which hangs over opposite ends of the load. Attached to each vertical side are covered void fillers, each adapted to substantially fill any lengthwise underhang and protect the load from end-to-end forces. The central area of the frame supports the vertical sides to which the void fillers are attached, thereby holding the void fillers in the proper position and also preventing dust from accumulating on the cargo.