Pallet Block Composite Core Outer Layer Pressure Molding
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Solution Overview
Problem
Prior pallet block solutions made from single materials like wood fibre agglomerate lack durability and robustness, requiring bonding that reduces their effectiveness, and often result in high material expenditure.
Innovation Solution
A pallet block comprising a wood particleboard core and a wood fibreboard outer layer, assembled through pressure molding without gluing, which provides enhanced robustness and resistance while minimizing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pallet blocks are made from single material (wood fibre agglomerate), then manufacturing is simple, but durability and robustness are reduced
Solution Approach 1:
The patent applies composite materials by combining wood fibreboard and wood particleboard in a single molded block. The wood fibreboard provides durability and robustness for the outer surfaces, while the wood particleboard provides structural strength for the core, resolving the contradiction between manufacturing simplicity and product reliability.
Solution Approach 2:
The patent applies local quality by assigning different materials to different regions of the block. The outer layers use wood fibreboard for protection and durability, while the inner core uses wood particleboard for structural support, allowing each region to have the optimal material properties for its specific function.
2Strength
If pallet blocks use bonding between different wood agglomerates, then structural elements can be fixed, but material expenditure increases
Solution Approach 1:
The patent applies parameter changes by utilizing the natural adhesive properties of wood resins that are activated under heat and pressure during molding. This eliminates the need for additional bonding agents between different wood agglomerates, achieving structural fixation while minimizing material expenditure.
3Quantity of substance
If pallet blocks are made from wood fibre agglomerate only, then material usage is high, but load-bearing capacity is reduced
Solution Approach 1:
The patent applies composite materials by integrating wood particleboard (higher density, better load-bearing properties) as the core material with wood fibreboard (good surface properties) as outer layers. This composite structure achieves high load-bearing capacity while optimizing material usage, as the particleboard core provides structural strength without requiring the entire block to be made of high-density material.
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 results in a pallet block that supports high weights, is resistant to breakdown, and has improved durability and load-bearing capacity, achieved through a simplified industrial process with thermosetting glue, allowing for easy identification and customization.
Implementation Method 1
the wood particleboard of the core (1) and the wood fibreboard of the outer layer (2) are glued together. This allows for a final product to be obtained which has high strength and high load bearing capacity, and which is compatible with the manufacture of a product by mould pressing. Preferably, said gluing of the wood particleboard of the core (1) and the wood fibreboard of the outer layer (2) is made by using thermosetting glue, more preferably thermosetting resin.
Implementation Method 2
the particle agglomerates are susceptible of achieving a high resistance by using heat-hardenable glue
Implementation Method 3
the assembly formed by the core (1) plus the outer layer (2) being obtained by subjecting it to pressure
Data Source
Figure 1
AI summary
This invention falls within the scope of pallets, more specifically pallet blocks, which form the base of a pallet or which are arranged between two platforms of a pallet, allowing the entry of forks from forklifts and other mechanisms of handling and stowing in warehouse, means of transport and containers. It is thus the object of this invention a pallet block (3) comprising a core (1) of wood particleboard and an outer layer (2) of wood fibreboard, the outer layer (2) at least partially coating the core (1), and the assembly formed by the core (1) plus the outer layer (2) being obtained by subjecting it to pressure. This enables a pallet block (3) to be obtained allowing high weights to be supported, without the whole block (3) being comprised of wood fibreboard, and with characteristics of robustness, thus avoiding the need for gluing between the elements.