Double-Wall Pallet Blocks for Forklift Impact and Weight Reduction
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Solution Overview
Problem
Conventional pallets made of solid wood suffer from damage due to contact with forklift tines, are heavy, and have high material costs based on wood volume and type, necessitating a more durable and cost-effective alternative.
Innovation Solution
A compression molding system that combines plastic and wood chips to create double wall blocks, using a first and second extruder to form inner and outer blocks, which are then pressed together to form a double wall structure, with a cooling system to stabilize the composite material and ensure a tight seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid wood support blocks are used, then strength and durability are improved, but weight and material cost increase
Solution Approach 1:
The patent applies composite materials by combining plastic and wood chips to create a support block that maintains strength while reducing weight and cost compared to solid wood blocks
2Strength
If solid wood support blocks are used, then strength and durability are improved, but material cost increases
Solution Approach 1:
The patent applies composite materials by combining plastic and wood chips to create a support block that maintains strength while reducing weight and cost compared to solid wood blocks
3Ease of operation
If forklift tines contact support blocks during alignment, then pallet handling is enabled, but support blocks may be damaged
Solution Approach 1:
The patent applies beforehand cushioning by creating a gap between the support block and the decks, which cushions against impact damage from forklift tine contact during pallet handling operations
4Ease of operation
If a gap is created between decks for receiving lifting members, then pallet handling is enabled, but support blocks become vulnerable to impact damage
Solution Approach 1:
The patent applies beforehand cushioning by creating a gap between the support block and the decks, which cushions against impact damage from forklift tine contact during pallet handling operations
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 provide durability and reduced weight compared to solid wood, while maintaining strength and reducing material costs through the use of recycled plastic and wood, forming a hermetic seal for enhanced structural integrity.
Implementation Method 1
a first extruder to output melted plastic, and a second extruder downstream from the first extruder and configured to mix the melted plastic with wood chips
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 configured to output melted plastic, a second extruder downstream from the first extruder and configured to mix the melted plastic with wood chips to output a composite material, a splitter downstream from the second extruder and configured to split a flow of the composite material between a first flow and a second flow, and an inner and outer block transfer valve downstream from the splitter and configured to receive the first flow and the second flow of the composite material. An inner block transfer valve and an outer block transfer valve may be configured to alternately direct the composite material between an inner block accumulator and an outer block accumulator.