Development of Lightweight Composite Pallets for Assembly Line of LCDs and PDPs

Aluminum pallets are used in assembly lines for LCDs (Liquid Crystal Displays) and PDPs (Plasma Display Panels). When used for high quality and large-sized LCDs and PDPs, these pallets have many problems, including heavy weight, and permanent deformation due to their own weight. To solve these problems, it is required that the pallets have light weight, high precision and multiple functions. In this study, stiff, flat, stable and lightweight composite pallets were developed to eliminate the problems associated with the current aluminum pallets. To withstand conditions of concentrated and distributed loads, the designed composite pallets consist of a honeycomb sandwich structure and patterned stiffeners. The composite pallets were made using a hot press under vacuum in a high temperature and high pressure environment. To achieve optimal weight, strength and utility of the composite pallet, the thicknesses of the skin and honeycomb core were determined, and mechanical experiments were conducted. Consequently, we developed highly durable and functional composite pallets with a weight reduction of about 60%.