Recycled Composite Pallet Assembly Durability
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Solution Overview
Problem
Conventional wooden pallets have limited durability and lifespan, leading to increased waste and costs, while stronger plastic or metal pallets are costly and heavy, contributing to deforestation and landfill issues.
Innovation Solution
A pallet assembly using composite materials formed from recycled post-consumer waste, comprising fibrous mass particles and thermoplastic binding materials, where the mass particles occupy 35-60% by weight and the binding material occupies 40-60% by weight, encapsulating the particles to create a durable and strong composite material for the pallet components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If conventional wooden pallets are used, then they are inexpensive and easy to manufacture, but they have limited durability and short lifespan leading to increased waste
Solution Approach 1:
The patent applies composite materials made from recycled post-consumer waste consisting of fibrous mass particles (35-60% by weight) bound with thermoplastic binding material (40-60% by weight) to manufacture pallet components. This composite structure provides enhanced durability and lifespan compared to conventional wood, while utilizing recycled materials to reduce waste generation and environmental impact.
2Strength
If plastic or metal pallets are used, then they have increased strength and lifespan, but they are costly to manufacture and heavier in weight
Solution Approach 1:
The patent employs composite materials combining fibrous mass particles with thermoplastic binding material to achieve a strength-to-weight ratio that exceeds conventional wood while remaining lighter than plastic or metal alternatives. The composite structure provides the necessary strength for pallet applications without the excessive weight of solid plastic or metal construction.
3Duration of action of stationary object
If plastic or metal pallets are used, then they have increased strength and lifespan, but they are costly to manufacture
Solution Approach 1:
The patent utilizes parameter changes by incorporating 35-60% fibrous mass particles by weight into the composite formulation, adjusting the composition to optimize both lifespan and manufacturing cost. This parametric approach to material composition achieves extended pallet lifespan while maintaining cost-effectiveness through the use of recycled materials and optimized binding material content.
4Ease of manufacture
If conventional wooden pallets are used, then they are easy to manufacture, but they contribute to deforestation and landfill issues
Solution Approach 1:
The patent converts harmful waste materials into beneficial products by using recycled post-consumer waste as the source of fibrous mass particles and thermoplastic binding material. This approach transforms potential landfill waste into valuable composite materials for pallet manufacturing, eliminating the need for deforestation while maintaining manufacturing simplicity.
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 pallets exhibit increased durability and strength, reduced waste, lower costs, and longer lifespan, with the potential for recycling, while minimizing landfill waste and deforestation, and offering competitive pricing compared to traditional wood pallets.
Implementation Method 1
the binding material consisting of a thermoplastic material at least partially derived from recycled post-consumer materials
Data Source
AI summary
A pallet is formed in which one or more components thereof is formed of a composite material. The composite material includes mass particles consisting of a fibrous material derived at least in part from recycled post-consumer materials and a binding material consisting of a thermoplastic material derived at least in part from recycled post-consumer materials. The mass particles and the binding material are mixed such that the binding material is liquified and each mass particle is fully encapsulated by the liquified binding material.