Pallet Base Honeycomb Structure Heat-Welded Binding
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Solution Overview
Problem
Existing pallet bases with internal honeycomb structures and metal sheets have complex, costly structures that are weak against fatigue and relative displacements, limiting their ability to support high loads and are not nestable for efficient stacking.
Innovation Solution
A pallet base with a plastic internal honeycomb structure, metal sheets extending over the entire structure, and outer plastic sheets joined through heat-welding of overhanging edges, providing a homogeneous and strong binding capable of supporting over one tonne of load, while simplifying the structure and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If complex laminates with many parts are used to achieve close binding between layers, then the binding strength is improved, but the manufacturing cost and device complexity increase significantly
Solution Approach 1:
The invention merges the binding function into the extrusion process itself. The interlocking profile is integrated into the honeycomb cell structure during extrusion, eliminating the need for separate binding layers or complex laminates. This combines multiple functions (structural support and binding) into a single manufacturing process and component design.
Solution Approach 2:
The interlocking profile serves multiple functions simultaneously: it provides structural support through the honeycomb geometry, creates binding between layers through the interlocking mechanism, and enables assembly without additional fasteners. This multi-functionality reduces the number of parts needed while maintaining binding strength.
2Strength
If complex laminates with many parts are used to achieve close binding between layers, then the binding strength is improved, but the manufacturing cost increases
Solution Approach 1:
The binding function is merged into the extrusion process. The interlocking profile is created during the single-step extrusion of the honeycomb structure, eliminating the need for separate binding layers or complex laminates. This combines multiple functions (structural support and binding) into a single manufacturing process and component design.
Solution Approach 2:
The invention uses a simple, easily manufacturable interlocking profile that can be produced through standard extrusion processes. The design favors simplicity and ease of manufacture over complex multi-layer laminates, accepting that the binding mechanism is straightforward rather than elaborate.
3Ease of manufacture
If the base structure is simplified to reduce manufacturing cost, then the ease of manufacture is improved, but the ability to support high loads and resistance to fatigue deteriorates
Solution Approach 1:
The base is segmented into a honeycomb structure with multiple cells arranged in a grid pattern. This segmentation provides high strength-to-weight ratio while maintaining ease of manufacture through extrusion processes. The cellular structure distributes loads across multiple segments, enhancing overall load capacity without requiring complex materials or assembly.
Solution Approach 2:
The invention uses composite construction combining the plastic honeycomb structure with metal sheets or reinforcement elements integrated into the design. This composite approach enhances load capacity and fatigue resistance while maintaining the simplicity and cost-effectiveness of the basic extruded structure.
4Ease of manufacture
If the base structure is simplified to reduce manufacturing cost, then the ease of manufacture is improved, but the reliability against fatigue and relative displacements deteriorates
Solution Approach 1:
The base is segmented into a honeycomb structure with multiple cells arranged in a grid pattern. This segmentation provides high strength-to-weight ratio while maintaining ease of manufacture through extrusion processes. The cellular structure distributes loads across multiple segments, enhancing overall load capacity without requiring complex materials or assembly.
Solution Approach 2:
The invention uses composite construction combining the plastic honeycomb structure with metal sheets or reinforcement elements integrated into the design. This composite approach enhances load capacity and fatigue resistance while maintaining the simplicity and cost-effectiveness of the basic extruded structure.
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 enables the pallet base to maintain mechanical stability under high loads without deformation, supports loads of more than one tonne, and allows for efficient nesting and stacking, addressing the limitations of previous designs.
Implementation Method 1
the metal sheets being provided with through-holes for passage of the ends of said edges, said ends being heat-welded to the outer sheets of plastic
Data Source
AI summary
A pallet base that comprises an internal honeycomb structure made of plastic, a metal sheet arranged on either side of the internal honeycomb structure that extends over an entirety of the internal honeycomb structure, and an outer sheet of plastic adjoined to each metal sheet. The internal honeycomb structure includes a plurality of honeycomb cells and a plurality of joining edges of the honeycomb cells. The joining edges of the honeycomb cells include ends that extend away from said honeycomb cells. The metal sheets may be provided with through-holes for passage of the ends of said joining edges. The ends of said joining edges may be heat-welded to the outer sheets of plastic.