Bakery tray

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Plastic bakery trays experience significant deflection when stacked and moved by a hand truck, leading to potential damage to the products and reduced tray lifespan due to the suspension of the base and shorter front and rear walls from the side walls, causing uneven load distribution.

Innovation Solution

The design incorporates upward-projecting support posts on the front and rear walls with downward-extending columns and a recessed base to transfer load through columns and support posts, reducing deflection and enhancing stability during handling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the base and front and rear walls are suspended from the side walls, then the trays can be stacked with shorter front and rear walls for access, but the center of the trays deflects upward when moved by a hand truck

Engineering Contradiction:

Improveaccess to baked goodsVSAvoidtray deflection

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The tray structure is segmented into distinct load-bearing elements: the side walls remain as primary support, while the front and rear walls are separated from direct suspension and instead supported by intermediate columns that extend downward to the base. This segmentation allows the front and rear walls to be shorter for accessibility while the columns provide dedicated support to prevent deflection when hand truck blades contact the base.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Columns are introduced as intermediary structural elements between the front and rear walls and the base. These columns act as mediators that transfer loads from the hand truck blade contact point through the base to the side walls, preventing direct transmission of deflection forces to the suspended front and rear walls while maintaining the shorter wall design for accessibility.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the blade of the hand truck is inserted under the base in the center of the front or rear walls, then the trays can be moved, but the center of the trays deflects upward causing potential damage

Engineering Contradiction:

Improvehandling by hand truckVSAvoidproduct damage from deflection

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The column structure provides beforehand cushioning by pre-establishing load paths from the front and rear walls through the columns to the base. When the hand truck blade contacts the base, the columns are already in position to absorb and distribute the impact forces, preventing sudden deflection that could damage products. The columns act as structural cushions that mitigate the harmful effects of handling forces.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The load path is segmented into distinct zones: the base receives direct contact from the hand truck blade, the columns transmit this load vertically, and the side walls provide ultimate support. This segmentation isolates the front and rear walls from direct impact forces, protecting products while enabling easy handling through the hand truck insertion point.

Inventive Principle:

Principle #1Segmentation

3Productivity

If the base and front and rear walls are suspended from the side walls, then the trays can be stacked, but the load distribution is uneven leading to reduced tray lifespan

Engineering Contradiction:

Improvestacking efficiencyVSAvoidtray lifespan

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The support system is segmented into multiple independent load-bearing paths: the side walls provide primary suspension for stacking, while the columns provide secondary support for the front and rear walls. This segmentation creates redundant load paths that distribute forces more evenly across the tray structure during stacking and handling, preventing concentration of stresses that would reduce tray lifespan while maintaining stacking efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The column structure provides beforehand cushioning by pre-establishing load distribution paths before stacking or handling operations. When trays are stacked or moved, the columns are already positioned to distribute loads evenly from the front and rear walls through to the base and side walls, preventing uneven stress concentration that would otherwise occur with direct suspension and reduce tray lifespan.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS10611518B2Bakery tray

Publication Date: 2020.04.07 REHRIG PACIFIC CO INC

AI summary

A tray includes a base and a pair of side walls extending upward from side edges of the base. Front and rear walls extend upward from front and rear edges of the base. The front and rear walls are shorter than the side walls. A plurality of support posts project upwardly from the upper edge of the front and rear walls. A lip is spaced outward of the front wall and the rear wall. Each lip includes a lower edge protruding downward to form columns aligned below the support posts. When stacked on a similar tray the columns contact the support posts of the similar tray to help support the front and rear walls. The base includes a recess below the columns for receiving the blade of a hand truck, which will transfer load throughout a stack of trays from columns to support posts.