Overmolded Two-Component Friction Element for Plastic Pallets
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Solution Overview
Problem
Existing plastic transportation systems, such as pallets, have inherently lower coefficients of friction compared to wood, leading to potential slippage issues, and existing methods to increase friction are either ineffective, costly, or problematic, including wear, contamination, and complex tooling requirements.
Innovation Solution
A two-component friction element is overmolded into the pallet, comprising a rigid outer carrier member and an elastomeric material, allowing for increased friction on both the top and bottom surfaces without the risk of dislodgement, using a multi-cavity injection molding process that allows for various shapes and configurations, including recesses for mechanical locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If adhesive-backed friction tape is applied to increase friction, then friction coefficient is improved, but adhesion is difficult to achieve and tape can contaminate recycling stream
Solution Approach 1:
The friction element is merged with the pallet structure through overmolding, creating an integrated assembly where the friction element becomes a permanent part of the pallet. This eliminates adhesion issues by replacing adhesive bonding with mechanical integration through the overmolded connection.
Solution Approach 2:
The friction element uses composite construction with a rigid outer carrier member and an elastomeric friction material interior, combining materials with different properties to achieve both structural integrity and high friction coefficient while being securely integrated into the pallet.
2Force
If spin disks are spin-welded to increase friction, then friction coefficient is improved, but material choices are limited and can only be placed on well supported areas
Solution Approach 1:
The friction element employs composite materials with a rigid outer carrier member made from pallet-compatible material and an elastomeric friction material interior, providing both structural integrity and high friction while allowing versatile material selection that spin-welded disks cannot achieve.
Solution Approach 2:
The friction element is segmented into distinct functional components: the rigid outer carrier member for structural support and integration, and the elastomeric friction material interior for friction enhancement, allowing each component to be optimized independently.
3Force
If integrated multi-shot friction elements are used, then friction coefficient is improved, but very expensive tooling is required and material selection is very limited
Solution Approach 1:
The manufacturing process is segmented into separate steps: first forming the rigid outer carrier member, then forming the elastomeric friction material interior, and finally integrating the friction element into the pallet through overmolding. This avoids the need for complex multi-shot injection tooling while achieving the same integrated result.
Solution Approach 2:
The friction element components are preliminarily formed separately before final integration into the pallet. The rigid outer carrier member is formed first, then the elastomeric material is added, and finally the complete friction element is overmolded into the pallet structure.
4Force
If elastic grommets are snapped-in to increase friction, then friction coefficient is improved, but grommets can fall out in use
Solution Approach 1:
The friction element is merged with the pallet structure through overmolding, creating a permanent integrated assembly. This eliminates the risk of grommets falling out by replacing snap-fit retention with mechanical integration through the overmolded connection that permanently secures the friction element to the pallet.
5Force
If pallet is roughed up after molding to increase friction, then friction coefficient is improved, but friction increases only slightly and process creates dust and noise
Solution Approach 1:
Instead of modifying the existing plastic surface, the invention integrates a composite friction element with elastomeric material that inherently provides high friction coefficient, eliminating the need for roughening processes that generate dust and noise.
6Force
If molded textures or spikes are formed on pallet surface, then friction coefficient is improved, but friction increases only slightly and spikes can damage product
Solution Approach 1:
The friction element uses elastomeric material that provides high friction through its material properties rather than through aggressive surface textures or spikes, eliminating product damage risk while achieving superior friction enhancement.
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 solution provides consistent and durable increased friction on plastic pallets, suitable for all applications, including food transportation, without the drawbacks of existing methods, such as wear or contamination, and allows for optional placement on either surface.
Implementation Method 1
Increasing the friction improves the handling property of loaded and unloaded systems
Implementation Method 2
injecting a rigid material into a first cavity of a multi-cavity injection mold to form the outer carrier member
Implementation Method 3
injecting an elastomeric material into the cavity of the rigid outer carrier member
Implementation Method 4
molding over an outer surface of the carrier member of the first friction element in the mold for the transportation system
Data Source
AI summary
The invention is directed to an overmolded two-component friction element in a plastic pallet and to a method for forming the pallet. The friction element includes a rigid outer carrier member and an elastomeric material that is exposed at one or more ends. The friction element is first formed in an injection mold, and then is placed in a pallet mold. Resin is injected into the pallet mold around the sides of the friction element leaving the exposed elastomeric material form part of the pallet surface.