Pallet Block Press Molding With Internal Steam Curing
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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, which leads to material waste and inefficiencies.
Innovation Solution
A method involving precise mass dosing of wood scrap and binder components, combined with internal heat application through a forming mandrel to accelerate resin cross-linking, eliminating the need for external cutting and reducing production time to under 3 minutes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wooden pallets are used, then they are easy to manufacture and handle, but they deteriorate when exposed to moisture and chemicals, requiring frequent replacement
Solution Approach 1:
The pallet block combines wood with plastic materials to create a composite structure. The wood provides structural strength while the plastic coating or core provides moisture and chemical resistance, eliminating the deterioration issues of conventional wooden pallets without requiring complete material replacement.
Solution Approach 2:
The invention changes the material parameters of the pallet by incorporating plastic components into the wooden structure. This parameter change transforms the pallet from being moisture-sensitive to being moisture-resistant, while maintaining ease of manufacture through standardized composite construction methods.
2Reliability
If metal pallets are used, then they resist moisture and chemicals, but they are expensive and can be damaged by dropping
Solution Approach 1:
The composite pallet block uses wood as the primary structural material which is inherently impact-resistant, while incorporating plastic elements that provide moisture and chemical resistance. This composite approach achieves the reliability of metal without the brittleness and high cost.
Solution Approach 2:
The pallet applies different material properties to different parts of the structure - wood provides impact resistance and structural strength, while plastic provides moisture and chemical resistance. This local differentiation of material qualities optimizes both strength and reliability.
3Reliability
If plastic pallets are used, then they resist moisture and chemicals, but they are costly and lack structural strength
Solution Approach 1:
The pallet block uses wood as the primary load-bearing material to provide structural strength, while incorporating plastic components that provide moisture and chemical resistance. This composite structure achieves the reliability of plastic without sacrificing the structural strength required for pallet functionality.
4Reliability
If wooden pallets are treated with preservatives, then they gain resistance to moisture and chemicals, but the treatment process becomes more complex and environmentally concerning
Solution Approach 1:
Instead of chemically treating wood with preservatives, the invention uses composite construction with plastic materials that inherently provide moisture and chemical resistance. This eliminates the need for complex chemical treatment processes while achieving the same reliability protection.
Solution Approach 2:
The invention converts the potential harm of moisture and chemical exposure into a benefit by using plastic materials that are naturally resistant to these elements. This eliminates the need for harmful chemical treatments and simplifies the manufacturing process.
Data Source
Figure 1
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.