Bidirectional Reinforcing Elements for Lightweight, Low-Flammability Pallets
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Solution Overview
Problem
Conventional plastic pallets struggle to meet stringent flammability regulations while maintaining lightweight and durable characteristics.
Innovation Solution
A plastic pallet design featuring bidirectional intersecting reinforcing elements, where elongated reinforcing elements are inserted into channels within a unitary plastic body, reducing the amount of flammable material and enhancing structural rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional plastic pallets are used to maintain lightweight and durable characteristics, then weight and durability are improved, but flammability regulations cannot be met
Solution Approach 1:
The pallet combines plastic material with metal reinforcing elements to create a composite structure. The metal elements (steel or aluminum) provide non-flammable reinforcement while the plastic provides lightweight durability, resolving the contradiction between durability and flammability resistance
Solution Approach 2:
The pallet is segmented into distinct functional zones: plastic body sections for lightweight durability and metal reinforcing elements for structural strength and fire resistance. This segmentation allows each material to perform its optimal function without compromising the other
2Object-affected harmful factors
If reinforcing elements are added to meet flammability regulations, then flammability resistance is improved, but structural complexity increases
Solution Approach 1:
The metal reinforcing elements are merged with the plastic body through integrated channels and recesses. The reinforcing elements are positioned within molded-in channels of the plastic body, creating a unified structure that reduces overall complexity despite adding fire-resistant components
Solution Approach 2:
The metal reinforcing elements serve multiple functions: providing structural strength, resisting fire, and acting as nesting surfaces for adjacent pallets. This multi-functionality justifies the added structural elements by delivering multiple benefits simultaneously
3Stability of the object's composition
If bidirectional intersecting reinforcing elements are deployed, then structural rigidity is enhanced, but manufacturing complexity increases
Solution Approach 1:
The plastic body is pre-formed with molded-in channels and recesses during injection molding before the metal reinforcing elements are inserted. This preliminary preparation of the plastic body simplifies the subsequent assembly of the bidirectional reinforcing element grid
Solution Approach 2:
The metal reinforcing elements are nested within the plastic body structure, with longitudinal elements positioned in channels and transverse elements passing through apertures in the longitudinal elements. This nested arrangement achieves bidirectional rigidity while consolidating multiple components into a compact integrated structure
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2
AI summary
A pallet (100) having a unitary plastic body (102) with at least four legs (104a), and including two sets of channels (106, 108) extending parallel to its two dimensions D1 and D2. The pallet also includes a first set of elongated reinforcing elements (110) deployed within channels (106) and a second set of elongated reinforcing elements (112) deployed within channels (108). The first set of elongated reinforcing elements (110) have apertures (114) positioned so as to align with channels (108). Apertures (114) are sized and shaped to receive elongated reinforcing elements (112) passing through the apertures, resulting in an inter-engagement of elements (110) and (112) at multiple crossover locations (116) as they extend through the pallet.