Reinforced Multi-Layer Pulp Structure for Higher Load-Bearing Strength
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Solution Overview
Problem
Traditional pulp pallets exhibit low tensile, compressive, and annular compressive strength, limiting their load-bearing capacity and suitability for heavier goods, and are primarily used in lighter applications.
Innovation Solution
A multi-layer composite pulp product is developed, incorporating high-strength ductile materials like recycled plastic or metal mesh as reinforcement layers between pulp layers, fused after high-temperature shaping to enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional single-layer pulp material is used for pallet manufacturing, then the manufacturing process is simple and cost-effective, but the tensile strength, compressive strength, and load-bearing capacity are low
Solution Approach 1:
The patent applies composite materials by combining pulp material with reinforcement materials (such as metal mesh, plastic sheets, or fiber layers) to create a multi-layer composite structure. This composite approach significantly enhances the tensile strength, compressive strength, and load-bearing capacity of the pallet while maintaining a relatively simple manufacturing process involving layering and hot pressing.
Solution Approach 2:
The patent segments the pallet structure into multiple functional layers: pulp base layers providing cushioning and structural form, and intermediate reinforcement layers providing mechanical strength. This segmentation allows each layer to contribute its specific properties, resolving the contradiction between strength enhancement and structural complexity.
2Strength
If multi-layer composite structure with reinforcement materials is used, then the load-bearing capacity and strength are greatly increased, but the manufacturing process complexity increases
Solution Approach 1:
The patent merges the manufacturing of multiple layers into a single integrated hot pressing process. The pulp layers and reinforcement materials are stacked together in a mold and consolidated in one step through hot pressing, which simplifies the manufacturing process despite the multi-layer composite structure. This combining approach eliminates the need for separate assembly steps for each layer.
Solution Approach 2:
The patent utilizes parameter changes by applying controlled temperature and pressure during the hot pressing process. These parameter changes enable the consolidation of multiple layers into a unified composite structure with enhanced bonding, achieving high load-bearing capacity while maintaining manufacturing simplicity through process optimization.
3Reliability
If traditional pulp material is used, then the product is environmentally friendly and recyclable, but the structural integrity and durability for heavy goods are insufficient
Solution Approach 1:
The patent employs composite materials that combine environmentally friendly pulp with durable reinforcement materials. The pulp layers maintain the product's eco-friendly and recyclable characteristics, while the embedded reinforcement layers (metal mesh, plastic, or fibers) provide the necessary structural integrity and durability for heavy goods handling. This composite approach resolves the contradiction between reliability and structural complexity.
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 multi-layer composite pulp product significantly increases strength and load-bearing capacity, enabling its use in heavier goods handling and expanding applications to building materials like wall panels and decoration panels.
Implementation Method 1
After high temperature shaping, the reinforcement layer may be fused to the pulp layers adjacent to opposing sides of the reinforcement layer
Data Source
AI summary
Exemplary embodiments of a multi-layer composite pulp product comprise one or more pulp layers, and one or more reinforcement layers disposed therebetween. Each of these layers preferably include a respective pattern of opposingly-defined cavities and protrusions, wherein the mutual disposition of the layers results in their patterns axially aligning with one another. The reinforcement layers may be comprised of a recycled plastic, a metallic mesh or a metallic sheet. One example process for manufacturing a multi-layer composite pulp product may comprise fabricating a reinforcement layer, forming a soggy first pulp layer, placing a reinforcement layer on the soggy first pulp layer, forming a soggy second pulp layer, and positioning the soggy second pulp layer on the reinforcement layer. A precursor wet composite may thereby be formed, and may be dried at a selected heating temperature and under a selected pressure.