Fiber-Reinforced Pallet Base Layers for Reduced Flexural Displacement
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Solution Overview
Problem
Conventional wooden pallets lack the mechanical properties of plastic pallets, such as resistance to deformation, leading to increased material usage, weight, and manufacturing complexity, while plastic pallets face issues with corrosion and structural integrity.
Innovation Solution
A fiber-reinforced plastic pallet design with a base layer reinforced by a fiber layer, utilizing continuous fiber-reinforced materials like CFRTP tape, integrated through methods such as 3D printing and over-molding, to enhance structural strength and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plastic pallets are used instead of wooden pallets, then impact performance and durability are improved, but resistance to deformation deteriorates
Solution Approach 1:
The patent applies composite materials by combining plastic base material with fiber reinforcement (such as glass fibers, carbon fibers, or natural fibers) to create a hybrid structure that leverages the impact resistance of plastic and the deformation resistance of fibers, resolving the contradiction between these two mechanical properties
2Strength
If fiber reinforcement is added to plastic pallets, then structural strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes parameter changes by employing thermoplastic materials that can be melted and reformed during manufacturing, allowing fiber reinforcement to be integrated into the plastic matrix through heating and cooling cycles, thereby achieving complex composite structures through controlled thermal parameter changes rather than mechanically complex assembly processes
3Stability of the object's composition
If more material is used to improve mechanical properties, then resistance to deformation is improved, but weight increases
Solution Approach 1:
The patent employs composite materials with high strength-to-weight ratio fibers (such as carbon fibers or glass fibers) embedded in the plastic matrix, providing enhanced deformation resistance without proportionally increasing weight, as the fibers provide structural reinforcement with minimal mass addition
Solution Approach 2:
The patent applies local quality by strategically placing fiber reinforcement in specific high-stress regions of the pallet rather than uniformly throughout, optimizing the distribution of material to provide deformation resistance where needed while minimizing overall weight
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 fiber-reinforced pallets provide improved structural integrity, reduced flexural displacement, and weight reduction, while maintaining antimicrobial properties suitable for handling sensitive goods.
Implementation Method 1
moving the thermoplastic part relative to a heat source to form a melted surface on the thermoplastic part
Implementation Method 2
cooling said first portion of the plasticized material to permanently fuse it to the surface of the thermoplastic part
Data Source
AI summary
A reinforced plastic pallet includes a pallet deck having a lower deck surface and an opposing upper deck surface, and the upper deck surface is configured for contacting goods. The reinforced plastic pallet includes one or more pallet legs extending between the lower deck surface and a base layer, wherein the base layer is reinforced with a fiber layer. A method for manufacturing a fiber-reinforced pallet having a thermoplastic part includes programming a controller with a pallet assembly profile; moving the thermoplastic part relative to a heat source to form a melted surface on the thermoplastic part; and depositing a fiber-reinforced material onto the melted surface according to the pallet assembly profile. The method may include entangling the fiber-reinforced material with the melted surface; and cooling the melted surface.