Polymeric Pallet Structural Integrity via Interlocking Blocks
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Solution Overview
Problem
Traditional fork lift pallets made of wood or metal are not durable enough and incur high replacement and manufacturing costs, with alternative materials being expensive and heavy, necessitating a need for improved, cost-effective, and durable pallets.
Innovation Solution
Polymeric formed structural components are used to create specialized fork lift pallets and containers with interlocking blocks and platforms, made through pressing, melting, injection, or casting, providing durability, corrosion resistance, and the ability to be nailed or screwed without starter holes, and can be infused with reinforcement ingredients like Nano-spheres or fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wood or metal materials are used for pallets, then structural strength is achieved, but durability is insufficient and replacement costs are high
Solution Approach 1:
The patent uses composite materials by embedding reinforcement ingredients (such as fibers, Nano-spheres, or other reinforcing agents) within the polymeric material to enhance structural strength and durability while maintaining the benefits of polymeric materials like corrosion resistance and reduced weight
Solution Approach 2:
The patent changes the material parameters by using polymeric material with specific properties (density, strength, flexibility) that differ from traditional wood or metal, optimizing the balance between durability, weight, and manufacturing cost
2Ease of manufacture
If alternative materials are used to replace wood and metal, then manufacturing cost is reduced, but weight increases making shipping more expensive
Solution Approach 1:
The patent optimizes the polymeric material formulation to achieve the desired strength-to-weight ratio, ensuring the pallet is lightweight enough to reduce shipping costs while maintaining sufficient structural integrity for its intended use
3Weight of moving object
If alternative materials are used to replace wood and metal, then shipping cost is reduced, but structural integrity is insufficient requiring frequent replacement
Solution Approach 1:
The patent employs composite materials with reinforcement ingredients embedded in the polymeric matrix to enhance structural integrity, load-bearing capacity, and resistance to deformation, thereby eliminating the need for frequent replacement despite the lighter weight
4Object-affected harmful factors
If polymeric material is used for pallet construction, then corrosion resistance is achieved, but connection reliability without starter holes is insufficient
Solution Approach 1:
The patent incorporates pre-formed holes or embedded fastening features during the pallet manufacturing process, allowing for reliable connections without requiring starter holes to be drilled later, thereby maintaining connection reliability while preserving the corrosion-resistant properties of the polymeric 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 polymeric pallets offer improved structural integrity, corrosion resistance, and reduced shipping costs due to lighter weight, while being resistant to splitting and tearing, making them suitable for various industrial applications.
Implementation Method 1
Polymeric material is formed by pressing, melting, injection, casting, and/or combinations of several fabrication methods
Data Source
AI summary
A pallet comprising upper and lower platforms connected by a plurality of blocks. The upper platform includes a plurality of upper platform pedestals and the lower platform includes a plurality of lower platform pedestals. The lower platform pedestals are aligned with the upper platform pedestals such that the lower platform pedestals and the upper platform pedestals extend towards one another. The plurality of blocks interlockingly engage with and extend between the upper and lower platform pedestals to connect the upper and lower platforms. Each block includes an upper recess and a lower recess. The upper recess matches the shape of and receives one of the upper platform pedestals. The lower recess matches the shape of and receives one of the lower platform pedestals. The upper platform, the lower platform, and the plurality of blocks are made of a polymeric material.