Polymeric Pallet With Filled Inner Core
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Solution Overview
Problem
Wooden pallets are prone to rotting, woodworm infestation, are easily pierced, heavy, and difficult to recycle, making them unsuitable for robust and long-lasting storage and transportation of goods under adverse conditions.
Innovation Solution
A polymeric load carrying apparatus with a soft outer shell and stiff inner core, where the outer shell comprises less than 10% filler and the inner core comprises at least 15% filler, primarily using HDPE and mineral fillers like sand, with the inner core being foamed to enhance structural integrity and impact absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wooden pallets are used for storing and transporting goods, then they are easily manufactured and inexpensive, but they are susceptible to rotting, woodworm infestation, and have short working life
Solution Approach 1:
The patent changes the material parameter from natural wood to polymeric materials (HDPE), fundamentally altering the properties to eliminate rotting and woodworm infestation while maintaining manufacturability through injection molding processes
Solution Approach 2:
The patent uses composite polymeric materials with varying filler concentrations (0-10% in outer shell, 15-40% in inner core) to create a multi-layer structure that combines durability, impact absorption, and structural integrity
2Quantity of substance
If wooden pallets are used, then they are cost-effective, but they are relatively heavy and difficult to recycle
Solution Approach 1:
The patent changes the material density parameter by using polymeric materials with controlled filler content, achieving reduced weight compared to solid wood while maintaining cost-effectiveness through efficient material utilization and recyclability
3Strength
If homogeneous solid pallets are used, then they have high structural strength, but they lack impact absorption capability and are prone to damage
Solution Approach 1:
The patent applies local quality by creating distinct regions with different filler concentrations - the outer shell has low filler (0-10%) for impact absorption and flexibility, while the inner core has high filler (15-40%) for structural strength and stiffness
Solution Approach 2:
The patent uses composite materials with gradient filler distribution to create a multi-functional structure where the outer shell absorbs impact energy and the inner core provides structural support, eliminating the damage vulnerability of homogeneous designs
4Weight of moving object
If hollow pallets are used, then they reduce weight, but they have lower structural integrity and are more vulnerable to damage
Solution Approach 1:
The patent uses filled composite polymeric materials with controlled filler content to achieve weight reduction while maintaining structural integrity - the outer shell provides protection and the filled inner core provides strength, creating a more reliable design than hollow structures
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 apparatus provides improved durability, reduced weight, and extended working life by acting as an impact-absorbing layer, maintaining structural integrity and preventing damage better than traditional pallets, while being cost-effective and recyclable.
Implementation Method 1
The outer shell of the pallet therefore acts as an impact absorbing layer to prevent impact damage occurring to the inner core of the pallet
Implementation Method 2
the inner core composition is foamed
Data Source
AI summary
A polymeric load carrying apparatus (10) and method of manufacture is disclosed. The apparatus comprises an outer shell composition and a filled inner core composition within the outer shell composition. The outer shell composition comprises less than 10% filler, and preferably substantially no filler, by weight, and the inner core composition comprises more than 15% filler, and preferably at least 40% filler, by weight. The filler is preferably a mineral sand.