Assembled Load Carrier with Heat-Releasable Adhesive for Repair
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Solution Overview
Problem
Existing load carriers, such as pallets, made of wood, wood-plastic composites, or plastic, face challenges in repairability and recyclability due to damage from forklifts, moisture, and material incompatibilities, leading to laborious separation and disposal issues.
Innovation Solution
A modular design with heat-soluble or microwave-soluble adhesive bonds between components, allowing for easy disassembly and replacement of damaged parts using heat or microwave treatment, and the use of recyclable materials like wood, plastic, and composites.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If blocks are permanently glued to the upper element to enable wider material combination, then material compatibility and structural integrity are improved, but repairability and recyclability deteriorate
Solution Approach 1:
The patent uses thermoplastic adhesive that changes its physical state based on temperature. At bonding temperature, the adhesive is fluid and provides strong bonding. At service temperature, it remains solid providing structural integrity. For repair, heating re-melts the adhesive allowing disassembly. This parameter change (temperature-dependent viscosity) resolves the contradiction between strong permanent bonding and ease of repair.
Solution Approach 2:
The adhesive undergoes phase transitions between solid and liquid states through temperature control. During bonding, it transitions from solid to liquid to flow and fill gaps. During service, it remains solid for strength. During repair, heating causes it to melt again for disassembly. These controlled phase transitions enable both strong bonding and easy repairability.
2Ease of manufacture
If one-piece pallet design is used, then manufacturing simplicity is improved, but repairability deteriorates as damaged blocks cannot be replaced
Solution Approach 1:
The patent divides the pallet into separate modular components (upper element, blocks, adhesive) that can be independently manufactured and assembled. This segmentation allows individual damaged blocks to be replaced without replacing the entire pallet, resolving the contradiction between simple manufacturing and repairability.
3Ease of manufacture
If metal parts are used in wooden pallets for block attachment, then ease of manufacture is improved, but recyclability deteriorates due to contamination of recycling streams
Solution Approach 1:
The patent extracts and removes metal parts from the pallet structure by using entirely wooden components and wooden adhesive. This elimination of metal contamination enables complete recyclability of wooden pallets while maintaining ease of manufacture through traditional woodworking methods.
4Productivity
If automated repair processes are implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical fastening systems (screws, clips, interlocking mechanisms) with a thermal bonding system using heat-activatable adhesive. This substitution enables automated repair through simple heating and pressing operations rather than complex mechanical disassembly and reassembly, resolving the contradiction between productivity and device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient repair and reuse of load carriers by allowing individual components to be easily replaced and recycled, reducing mechanical damage and resource waste.
Implementation Method 1
adhesive bonds between components
Implementation Method 2
heat-soluble adhesive bonds... allowing for easy disassembly and replacement of damaged parts using heat
Implementation Method 3
microwave-soluble adhesive bonds... allowing for easy disassembly and replacement of damaged parts using microwave treatment
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to assembled load carriers with joints to which accessible load carrier elements such as superstructures, side parts, reinforcement elements or foot elements (10, 20, 30) are attached, wherein the connection of at least two load carrier elements (10, 20) is produced by a heat-soluble or microwave-soluble adhesive, and to a method for producing or repairing the assembled load carrier, wherein at least some of the surfaces to be joined are provided with adhesive for adhesive bonds; the connecting surfaces coated in this way are brought into contact at the connecting points, the parts to be joined are pressed against one another and the adhesive is activated, so that at least one adhesive bond is formed by setting the adhesive, which can be released if necessary, such as a necessary repair by heat exposure or microwave treatment of the at least one adhesive bond, for example in order to attach a replacement part.