Intermeshing Rib Plastic Panel for Concrete Pallets
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Solution Overview
Problem
The concrete masonry unit industry faces challenges in producing plastic panels that are dimensionally stable, wear-resistant, and cost-effective, as existing thermoplastic panels often warp during molding and require additional strengthening, which complicates recycling and increases production costs.
Innovation Solution
A novel plastic panel configuration featuring joinable portions with intermeshing ribs and optional reinforcing bars, allowing for efficient molding, strengthening, and assembly without the need for additional fasteners, enhancing stability and durability while facilitating recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If thermoplastic panels are molded without internal steel strengthening bars, then recycling is improved, but strength and rigidity deteriorate
Solution Approach 1:
The panel is divided into two separate halves that are joined together, with each half containing integrated steel strengthening bars. This segmentation allows the steel bars to be distributed across multiple smaller components during recycling, making separation and reclamation easier while maintaining strength in the assembled panel.
Solution Approach 2:
The panel uses a composite structure combining thermoplastic material with integrated steel strengthening bars within each half. This composite design provides the necessary strength and rigidity while the segmented nature facilitates future recycling by allowing the steel components to be separated from the plastic material.
2Stability of the object's composition
If molded plastic panels are made as single pieces, then structural integrity is improved, but molding difficulty and warping increase
Solution Approach 1:
The panel is manufactured as two separate halves that are later joined together. This segmentation reduces the size and complexity of each molding operation, making the molding process easier and reducing warping, while the joined structure maintains the necessary structural integrity for the application.
3Strength
If panel halves are joined with additional hardware or bonding agents, then joint strength is improved, but device complexity and cost increase
Solution Approach 1:
The steel strengthening bars are integrated within the panel halves themselves, and the joining process utilizes these bars to create the connection between halves. This merging of the strengthening function into the structural components eliminates the need for separate fasteners or bonding agents, reducing assembly complexity while maintaining joint strength.
Data Source
AI summary
A plastic panel which may be used as a production pallet in the production of unitary concrete masonry products includes first and second joinable portions. The portions each comprise a support backing including an outer surface and an inner face, and a plurality of ribs extending outwardly away from said inner face. The ribs of a first grouping thereof are parallel with one another and extend across a first area of the face in a first direction, and the ribs of a second grouping thereof extend across a second area of the face in a second direction which is not parallel with said first direction. The panel portions are configured, disposed and arranged so as to join with one another in generally overlapping and mated relationship with the outer surfaces disposed in spaced apart opposing relationship, with the first groupings of ribs of the respective portions disposed in intermeshing and mating relationship with each other, and with the second groupings of ribs of the respective portions also disposed in intermeshing and mating relationship with each other whereby to present said plastic panel.