Pallet Block Pressing with Forming Mandrel Steam Heating
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Solution Overview
Problem
Existing pallet block production methods are time-consuming due to lengthy resin curing processes and require post-processing, such as cutting to size, and are limited by volume dosing which affects density and material waste.
Innovation Solution
A method involving precise mass dosing and internal heat application through a forming mandrel to accelerate resin cross-linking, using a feeder and steam injection to ensure uniform density and eliminate cutting waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resin cross-linking is performed during pressing of pallet block, then binding strength is improved, but production time is significantly increased
Solution Approach 1:
The resin is pre-applied to the wood chips before pressing, so that the cross-linking process can begin immediately during pressing without waiting for resin application. This preliminary preparation eliminates the time-consuming post-pressing curing step while ensuring adequate binding strength through proper resin distribution.
Solution Approach 2:
The patent modifies the pressing parameters (temperature, pressure, time) to optimize the cross-linking process during pressing. By controlling these parameters, the resin cross-links efficiently during the pressing operation itself, reducing total production time while maintaining binding strength.
2Productivity
If volume dosing is used in press mold, then multiple blocks can be pressed simultaneously, but density control and material waste are problematic
Solution Approach 1:
The patent replaces volume-based dosing with mass-based dosing using a feeder equipped with a dosing scale. This substitution of the dosing mechanism enables precise control of material density while maintaining the ability to produce multiple blocks simultaneously, resolving the contradiction between productivity and manufacturing precision.
3Stability of the object's composition
If resin is introduced from outside by steam, then resin distribution is improved, but post-processing cutting is still required
Solution Approach 1:
The resin is applied to the wood chips before they are placed in the press mold, ensuring proper distribution from the outset. This preliminary application eliminates the need for post-pressing cutting operations, as the blocks achieve correct dimensions and properties during pressing itself.
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
Pallet blocks are produced efficiently with consistent density and size in under 3 minutes, reducing material loss and eliminating post-processing, while maintaining high quality.
Implementation Method 1
the pressed pallet block material fed into the press mould will be heated from the inside with the heat supplied to the central region of the pressed pallet block material
Implementation Method 2
heating the pressed pallet block material fed into the press mould
Data Source
AI summary
Wood scrap and binder components forming raw material (1) of a pallet block are prepared in accordance with predetermined mechanical properties of the pallet block to be produced with a mass equal to the predetermined mass of the finished pallet block. The prepared components are mixed and fed into a press mould (3) of a press die (2), pressed to size, and the binder is cross-linked applying heat externally by the aid of the side walls (11) of the press mould (3) and at the same time internally by applying heat to the central region of the pallet base material (1) via a central forming mandrel (14) conducting hot steam into the pressed the pallet block, thereby promoting the cross-linking of the pallet base material's binder in short time. The invention also relates to an apparatus implementing the method.