Recycled Plastic Pallet Composition Using Heterogeneous Waste

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Solution Overview

Problem

Existing plastic pallets are typically made from homogeneous virgin or recycled materials, lacking a sustainable and cost-effective solution using heterogeneous post-consumer and post-production waste materials.

Innovation Solution

A recycled plastic pallet composed of a mixture of secondary raw plastic materials, including a filler and a polyolefin-based color masterbatch, produced through low-pressure injection molding with a specialized plasticizing mixer and controlled injection parameters, ensuring homogeneity and recyclability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If homogeneous virgin or recycled materials are used for plastic pallets, then manufacturing simplicity and material consistency are maintained, but environmental sustainability and cost-effectiveness using post-consumer waste are compromised

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidenvironmental sustainability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies composite materials by creating a plastic pallet from heterogeneous recycled materials including post-consumer plastic waste, post-production residues, and mineral fillers. These diverse materials are combined through injection molding to form a unified structural component that achieves both sustainability goals and manufacturing feasibility.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent employs parameter changes by controlling the injection molding process parameters (temperature, pressure, injection rate) to ensure proper mixing and bonding of heterogeneous recycled materials. This allows the transformation of variable-quality post-consumer waste into a consistent, reliable pallet structure.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If heterogeneous post-consumer and post-production waste materials are used, then environmental sustainability is improved, but material homogeneity and manufacturing consistency deteriorate

Engineering Contradiction:

Improveenvironmental sustainabilityVSAvoidmaterial homogeneity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent uses an intermediary approach by introducing mineral fillers and color masterbatches as mediating components that facilitate the integration of heterogeneous recycled plastics. These intermediaries help uniform the material mixture and ensure consistent molding results despite the variability of post-consumer waste inputs.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent employs parameter changes by optimizing injection molding conditions (temperature profiles, pressure sequences, injection rates) to achieve proper mixing and homogenization of heterogeneous recycled materials during the molding process, transforming variable inputs into consistent outputs.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If recycled materials are used for pallet production, then cost-effectiveness and sustainability are improved, but material quality and structural reliability may worsen

Engineering Contradiction:

Improvecost-effectivenessVSAvoidstructural reliability

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent applies composite materials by combining recycled plastics with mineral fillers (such as ground calcium carbonate or滑石粉) to enhance the mechanical properties of the final pallet structure. This composite approach compensates for potential weaknesses in recycled materials while maintaining cost-effectiveness.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent employs parameter changes by optimizing the injection molding process parameters including temperature, pressure, and injection rate to ensure proper material flow, filling, and bonding. These controlled parameters ensure that recycled materials achieve the necessary structural integrity for pallet applications.

Inventive Principle:

Principle #35Parameter changes

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 pallet achieves environmental sustainability and cost-effectiveness by utilizing recycled materials, with high reliability and ease of recycling, while maintaining structural integrity and low production costs.

Implementation Method 1

The plasticizing process occurs both by the mechanical action of a screw and by the application of heat using a temperature control system

Methodology Applied

Scientific EffectPlasticization:

Implementation Method 2

The application of heat using a temperature control system, with various temperature profiles that can vary from 180°C to 200°C approximately

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 3

Once the plastic conglomerate has been injected into the mold, the system cools it

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentEP4596438A1Recycled plastic pallet

Publication Date: 2025.08.06 CPR SYST SOC COOP

AI summary

A recycled plastic pallet, provided by means of a mixture of: - a first component, constituted by a secondary raw plastic material; - a second component, constituted by a secondary raw plastic material with a filler function; - a third component, constituted by a polyolefin-based color masterbatch.