Foamed Resin Pallet with Selective Resin-Sheet Reinforcement
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Solution Overview
Problem
Foamed resin pallets face challenges in maintaining thermal insulation and cushioning properties while ensuring surface strength, particularly when the entire surface is covered with a resin sheet, which reduces the effectiveness of the inherent properties of foamed resin.
Innovation Solution
A pallet design with a foamed resin body and a resin sheet that covers the bottom, sides, and step portions but not the loading surface, combined with exhaust holes and separate legs, ensuring the foamed resin directly contacts the goods for thermal insulation and cushioning, while the resin sheet enhances surface durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the entire surface of the foamed resin pallet is covered with a resin sheet, then the surface strength and durability are improved, but the thermal insulation performance and cushioning property are reduced
Solution Approach 1:
The resin sheet is selectively applied only to specific areas of the pallet (bottom surface, side surfaces, and step portions) while leaving the loading surface uncovered. This local differentiation allows the pallet to have enhanced surface strength where needed while maintaining the thermal insulation and cushioning properties of the foamed resin where goods are placed.
2Duration of action of stationary object
If the entire surface of the foamed resin pallet is covered with a resin sheet, then the surface durability is improved, but the cushioning property is reduced
Solution Approach 1:
The resin sheet coverage is localized to areas that do not contact goods (bottom and side surfaces), while the loading surface remains as uncovered foamed resin to provide cushioning protection to goods. This resolves the contradiction by applying durability enhancement only where structurally necessary.
3Strength
If the resin sheet covers the loading surface, then the surface strength is improved, but the thermal insulation performance cannot be sufficiently exhibited
Solution Approach 1:
The loading surface is deliberately left uncovered to maintain optimal thermal insulation performance, while other surfaces receive the resin sheet reinforcement. This spatial differentiation of material properties resolves the contradiction between strength and thermal insulation.
4Device complexity
If the resin sheet is stretched over the step portion, then the sheet thickness is reduced, but the surface strength may be compromised
Solution Approach 1:
The step portion is designed with a down-step geometry that pre-accommodates the resin sheet during the vacuum forming process. This preliminary structural design allows the sheet to be stretched and thinned in the step region without compromising overall strength, as the step geometry provides structural support.
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 design maintains high thermal insulation and cushioning properties for goods while enhancing the pallet's surface strength and durability, preventing resin sheet peeling and ensuring effective protection against shocks and heat transfer.
Implementation Method 1
a resin sheet integrated by vacuum-forming from the bottom surface of the pallet
Implementation Method 2
the foamed beads, which constitute the foamed resin pallet, contain air in their almost entire volume, and therefore have low thermal conductivity
Implementation Method 3
since the pallet made of foamed resin has a cushioning property unique to foamed resin, goods-conveyed can be protected from shocks
Data Source
Figure 1A~1C
Figure 2
Figure 3A~3C
AI summary
An object of the present invention is to provide a pallet having excellent thermal insulation performance and cushioning property with respect to goods-conveyed while ensuring the strength of the outer surface of the pallet. The pallet 1 comprises the plate-like pallet body 2 made of foamed resin, the plurality of legs 3 provided on the bottom surface 22 of the pallet body 2, and the resin sheet 4 integrated from the bottom surface side of the pallet body 2 by vacuum-forming. Further, the top surface 21 of the pallet body 2 includes the loading surface 20 on which goods-conveyed are placed, and the step portion 24 formed in a shape down-step from the outer peripheral edge of the loading surface 20 to the side surface of the pallet body 2. The resin sheet 4 covers the bottom surface 22 of the pallet body 2, the legs 3, the side surface 23 and the step portion 24 of the pallet body 2, and the loading surface 20 is not covered with the resin sheet 4.