Recycled Plastic Pallet Support Block for Weight Reduction
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Solution Overview
Problem
Conventional wood pallets are heavy, expensive, and environmentally problematic due to their wood-intensive construction, leading to increased manufacturing costs, transportation fuel consumption, and waste disposal issues.
Innovation Solution
The use of recyclable and recyclable pallet support blocks made of recycled plastic material, which replace wood stringers and can eliminate bottom deck boards, reducing wood usage and incorporating compression-resistant designs for structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wood stringers and deck boards are used to construct a pallet, then the pallet has sufficient structural strength and compression resistance, but the pallet becomes heavy, expensive, and environmentally problematic
Solution Approach 1:
The patent changes the material parameter from wood to recycled plastic, fundamentally altering the weight and environmental characteristics while maintaining structural performance. The plastic support blocks provide the necessary compression resistance and structural strength without the weight penalty of wood, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The patent uses composite construction within the support blocks themselves, incorporating reinforcement elements and multi-layer plastic structures to achieve wood-like strength. The center support structure with lateral supports and the flange designs create a composite system that delivers sufficient structural integrity while maintaining the weight advantages of plastic material.
2Strength
If wood stringers and deck boards are used to construct a pallet, then the pallet has sufficient structural strength and compression resistance, but the manufacturing cost increases
Solution Approach 1:
The patent changes the material parameter from wood to recycled plastic, which has different cost characteristics. Recycled plastic material reduces manufacturing costs while maintaining structural strength, eliminating the need for expensive wood procurement and processing while providing comparable or superior performance.
Solution Approach 2:
The patent employs support blocks made from recycled plastic that can be manufactured at lower cost than wood. The design allows for economical production through molding processes, and the blocks can be replaced individually if damaged, reducing overall manufacturing and maintenance costs while maintaining necessary structural strength.
3Strength
If wood stringers and deck boards are used to construct a pallet, then the pallet has sufficient structural strength and compression resistance, but the environmental impact increases due to wood waste and mold susceptibility
Solution Approach 1:
The patent changes the material parameter from wood to recycled plastic, fundamentally altering the environmental profile. Plastic material is resistant to mold and mildew, eliminating biological degradation issues. The use of recycled plastic also reduces environmental impact by repurposing waste materials, while maintaining the structural strength needed for pallet applications.
Solution Approach 2:
The patent employs support blocks made from recycled plastic that eliminate the environmental problems associated with wood disposal. The plastic material does not rot or support mold growth, and when the blocks reach end-of-life, they can be recycled again, creating a sustainable cycle that reduces environmental impact while maintaining structural strength throughout their service life.
4Strength
If conventional wood pallets are used, then the pallets have sufficient structural integrity, but the transportation efficiency decreases due to weight and non-nestable design
Solution Approach 1:
The patent changes the material parameter from wood to recycled plastic, which enables the support blocks to be designed with nesting capabilities. The plastic material allows for thinner wall sections and more compact geometries that can be stacked and nested efficiently, dramatically improving transportation efficiency while maintaining structural integrity through optimized block designs with centers and lateral supports.
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
This solution decreases the weight and manufacturing costs of pallets, allows for more efficient transportation by making pallets nestable, and reduces environmental impact through reduced wood waste and recyclability, while maintaining structural integrity and preventing mold/mildew issues.
Implementation Method 1
The center support structure has a tubular center column that provides compression resistant strength to the center support structure
Implementation Method 2
The center support structure also includes first and second sidewalls on opposite sides of the center column. The center support structure further includes first and second webs on opposite sides of the center column. The first and second sidewall and the first and second webs reinforce the center column to resist compression forces
Data Source
AI summary
A pallet support block is constructed of recycled plastic material that is also recyclable. The use of the pallet support block in pallet construction reduces the amount of wood used in the pallet construction and thereby makes the pallet lighter and reduces the cost of manufacturing the pallet.