Double-Wall Pallet Blocks Using Nested Hollow Composite Cores

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Solution Overview

Problem

Conventional wooden pallet support blocks are prone to damage from forklift tines and are heavy, increasing the pallet's weight and cost, while alternative materials lack durability and efficiency.

Innovation Solution

A compression molding system that combines recycled plastic and wood chips to create double wall blocks with a hollow center, using a multi-stage process to form inner and outer blocks that interlock, providing strength and reduced weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If solid wood support blocks are used, then strength and durability are improved, but weight increases

Engineering Contradiction:

Improvesupport block strengthVSAvoidpallet weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The support block is divided into an outer block and an inner block, where the inner block is inserted into a cavity of the outer block. This segmentation creates a hollow structure that reduces weight while maintaining structural integrity through the interlocking design of the two blocks.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The inner block is nested within the outer block, with the inner block's outer surface inserted into the cavity of the outer block. This nesting arrangement reduces material usage and overall weight while preserving the load-bearing capacity through the combined structure.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If solid wood support blocks are used, then durability is improved, but material cost increases

Engineering Contradiction:

Improvesupport block durabilityVSAvoidwood material quantity

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The support block is segmented into outer and inner blocks, allowing the use of wood composite material with higher plastic content (at least 30% by volume) which reduces overall wood consumption while maintaining durability through the reinforced composite structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support block uses a composite material consisting of wood chips and plastic (at least 30% plastic by volume), creating a durable wood-plastic composite that reduces reliance on pure wood while maintaining or enhancing durability and resistance to forklift damage.

Inventive Principle:

Principle #40Composite materials

3Weight of moving object

If hollow center design is used, then weight is reduced, but structural integrity may worsen

Engineering Contradiction:

Improvesupport block weightVSAvoidstructural integrity

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The inner block is nested within the outer block, creating a reinforced hollow structure. The inner block's outer surface fits into the cavity of the outer block, providing internal support that maintains structural integrity while reducing weight through the hollow center design.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The use of wood-plastic composite material (at least 30% plastic by volume) in the hollow block structure provides enhanced durability and structural integrity, compensating for the reduced material quantity while maintaining load-bearing capacity and resistance to forklift tine damage.

Inventive Principle:

Principle #40Composite materials

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 offer durability and reduced weight compared to solid wood, maintaining structural integrity and reducing material costs.

Implementation Method 1

a first extruder to output melted plastic

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

a second extruder downstream from the first extruder and configured to mix the melted plastic with wood chips

Methodology Applied

Scientific EffectMixing:

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

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 4

The inner and outer block molds may be cooled while under pressure to allow the composite material to stabilize

Methodology Applied

Scientific EffectCooling: Cooling

Implementation Method 5

The inner block coolant system circulate a coolant through each inner block mold when the composite material therein is under pressure

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20250375925A1Compression molded double wall blocks for a pallet and associated methods

Publication Date: 2025.12.11 CHEP TECH PTY LTD

AI summary

A compression press is provided, comprising: a frame; a movable lid carried by said frame and having an opening extending therethrough; an enclosure carried by said frame and comprising a core movable between a retracted position and an extended position, with said core aligned with the opening in said lid; a first hydraulic stage carried by said frame; and a second hydraulic stage carried by said frame and configured to apply additional pressure on said lid and said core in the extended position within the cavity. The first hydraulic stage is configured to perform the following: move said core from the retracted position to the extended position and move said lid and said core in the extended position to contact a mold having a cavity with material deposited therein, with pressure being applied to said lid and said core in the extended position within the cavity.