Interlocking Monolithic Foam Tiles for Pallet Repurposing
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Solution Overview
Problem
Conventional shipping pallets incur high environmental and operational costs due to their single-purpose design, contributing to increased fuel consumption and waste, while reducing the capacity for transporting goods.
Innovation Solution
The development of interlocking pallet caps and tiles that can be used to create an expandable, raised flooring system, utilizing a monolithic structure with shaped protrusions and apertures for secure attachment, made from materials like plastic and composite materials, allowing for the reuse of discarded pallets and reducing material requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional single-purpose pallets are used for shipping, then goods can be transported, but environmental costs and fuel consumption increase while cargo capacity is reduced
Solution Approach 1:
The patent transforms single-purpose shipping pallets into multi-functional units that can serve both as transport platforms and as flooring components. The interlocking tile design allows pallets to be disassembled and reconfigured into permanent flooring structures, eliminating the need for separate flooring materials and reducing the frequency of pallet replacement, thereby reducing overall material consumption and associated energy costs.
Solution Approach 2:
The invention enables the recovery and reuse of pallet materials after their primary shipping function is completed. By designing pallets with interlocking features that allow them to be reconfigured into flooring tiles, the system recovers the material value of the pallets and extends their service life, reducing the need to manufacture new materials and the energy associated with production and disposal.
2Strength
If conventional pallets are used, then goods can be supported during transport, but the weight of pallets increases fuel cost and reduces cargo capacity
Solution Approach 1:
The patent divides the pallet structure into interlocking tile segments that can be independently configured. This segmentation allows for optimization of each tile's weight-to-strength ratio, and enables the system to use only the necessary number of tiles for each application, reducing total weight compared to traditional full-pallet solutions while maintaining required support capacity.
3Productivity
If wooden pallets are manufactured and disposed of after use, then shipping needs are met, but environmental resources are consumed and waste is generated
Solution Approach 1:
The invention prevents the disposal of pallet materials by designing them to be recovered and reconfigured into flooring applications. The interlocking tile design ensures that pallet materials can be easily disassembled and reused, eliminating the waste stream associated with traditional pallet disposal and reducing the need for continuous manufacturing of new pallets.
Solution Approach 2:
By enabling pallets to serve dual purposes as both shipping containers and permanent flooring structures, the invention extends the useful life of the material and eliminates the need for separate flooring materials, thereby reducing overall material consumption and waste generation while maintaining shipping productivity.
4Loss of substance
If interlocking tiles are used to create flooring systems, then material usage is reduced and environmental impact is minimized, but manufacturing complexity increases
Solution Approach 1:
The patent segments the flooring system into standardized interlocking tiles that can be manufactured using simplified processes and then assembled into complex configurations. This segmentation allows each tile to be produced with consistent, simple geometry while the overall system achieves complexity through the arrangement and interlocking of these standardized units, reducing manufacturing complexity compared to producing large, custom-fitted flooring pieces.
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
This solution reduces material usage, minimizes environmental impact, and increases the efficiency of cargo transport by allowing pallets to be repurposed into a customizable flooring system, thereby lowering operational costs and enhancing cargo capacity.
Implementation Method 1
a method manufactures a monolithic interlocking tile by injecting a closed-cell foam material into a mold to form a monolithic structure
Data Source
AI summary
A monolithic interlocking tile, manufacturing method, and covering are disclosed. A closed-cell foam material is injected into a mold to form a monolithic structure having a first surface, a second surface offset and opposite the first surface, the first surface including a first lip located at two adjacent sides of the structure with a plurality of shaped protrusions, and the second surface including a second lip located at two other adjacent sides of the structure and forming a plurality of shaped apertures matching in number and shape with the plurality of protrusions; and a recess formed in the second lip and forming a hole for receiving a fastener to secure the monolithic structure to a supporting structure. Multiple monolithic interlocking tiles are interlocked together to form the covering for a floor, wall, ceiling, or roof.