Double-Wall Pallet Blocks Using Wood-Plastic Composite Molding
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Solution Overview
Problem
Conventional wooden pallet support blocks are prone to damage from forklift tines and are heavy, increasing the pallet's weight and cost.
Innovation Solution
A compression molding system that produces double wall blocks using a composite material of 50% plastic and 50% wood, formed by extrusion and cooling processes to create inner and outer blocks that interlock, reducing weight and providing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid wood support blocks are used, then strength and durability are improved, but weight increases
Solution Approach 1:
The support block is divided into an outer block and an inner block, where the inner block is a hollow structure. This segmentation maintains the external dimensions and strength of a solid block while removing internal material to reduce weight. The hollow inner block is positioned within the outer block, creating a lightweight yet structurally sound support block that resists forklift tine impacts without the full weight of solid wood.
2Reliability
If solid wood support blocks are used, then durability is improved, but cost increases
Solution Approach 1:
The support block combines wood and plastic materials in a composite structure. The outer block is made of plastic while the inner block is made of wood, creating a hybrid component that leverages the durability and impact resistance of plastic with the structural properties of wood. This composite approach reduces material costs compared to using solid premium wood throughout, while maintaining or improving durability through the protective outer shell.
3Weight of moving object
If hollow inner block structure is used, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The hollow inner block is pre-formed as a separate component before being inserted into the outer block. The inner block is manufactured with its hollow structure already in place, then positioned within the outer block's cavity. This preliminary formation of the inner block simplifies the overall manufacturing process compared to creating the hollow structure as part of a single complex molding operation, as it allows for modular production and assembly.
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
The double wall blocks offer reduced weight and enhanced durability while maintaining strength, addressing the issues of damage and weight associated with solid wood blocks.
Implementation Method 1
a first extruder to output melted plastic
Implementation Method 2
a second extruder downstream from the first extruder and configured to mix the melted plastic with wood chips to output a composite material
Implementation Method 3
at least one inner block press aligned with the at least one inner block mold to press the composite material in the at least one inner block mold into a desired shape
Implementation Method 4
The inner and outer block molds may be cooled while under pressure to allow the composite material to stabilize
Data Source
AI summary
A compression molding system includes a first extruder to output melted plastic, and a second extruder downstream from the first extruder to mix the melted plastic with wood chips to output a composite material. A transfer valve alternately directs the composite material between inner block molds and outer block molds. Each inner block mold has an inner block press associated therewith to press the composite material into a desired shape of an inner block having an opening on one side. Each outer block mold has an outer block press associated therewith to press the composite material into a desired shape of an outer block having an opening on one side. A press assembly presses one of the inner blocks into the opening in one of the outer blocks to form a double wall block.