Bakery Tray Interlocking Projection Resists Wall Deflection
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Solution Overview
Problem
Bakery trays experience outward deflection of side walls when stacked due to uneven weight distribution, as the weight from upper trays bears on the bottom tray at points outward of the drag rails, leading to instability and potential twisting of the side walls.
Innovation Solution
The design incorporates a projection on one side wall aligned with the upper edge, which interlocks with the upper edge of an identical tray to resist outward deflection, and platforms extending inwardly from the walls to support smaller trays, along with interlocking recesses for automated handling equipment, ensuring stable stacking and weight distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If trays are stacked with feet on drag rails, then stacking capability is improved, but side wall stability deteriorates due to outward deflection
Solution Approach 1:
The projection on the side wall creates a preliminary counteracting force against the outward deflection caused by stacked tray weight. The projection extends beyond the drag rail and interlocks with the recess in the upper tray, preventing the side wall from twisting outward before the deflection can occur.
Solution Approach 2:
The projection and recess form an intermediary interlocking mechanism between stacked trays. This intermediary structure transfers the weight load from the feet through the projection-recess interface to the side wall, distributing the force and preventing direct outward pressure on the side wall.
2Length of stationary object
If weight is borne at points outward of drag rails, then stacking height is improved, but structural integrity deteriorates due to side wall twisting
Solution Approach 1:
The projection extends in a new dimension beyond the drag rail, creating an interlocking feature that operates in the lateral direction. This dimensional extension allows weight to be borne at points outward of the drag rails while the projection-recess interface provides lateral support to prevent side wall twisting.
3Stability of the object's composition
If projection interlocks with upper edge, then resistance to outward deflection is improved, but device complexity increases
Solution Approach 1:
The projection is merged with the side wall structure, and the recess is merged with the upper edge structure. This integration means the interlocking feature is formed as part of the existing tray geometry rather than as a separate component, minimizing the increase in device complexity while providing the needed resistance to outward deflection.
Data Source
AI summary
A tray includes a base and a plurality of walls extending upward from the base. In one feature, a first wall of the plurality of walls may include a projection outward from the first wall. The projection is aligned with an upper edge of the first wall, such that the projection is outward of a portion of the upper edge of the first wall. The projection of an identical upper tray stacked on the tray would interlock with the upper edge of the first wall to resist outward deflection of the upper edge of the first wall of the tray. In another feature, a platform may extend inward from at least one of the walls to support smaller trays stacked thereon. In another feature, an exterior of each of the side walls may include an interlocking recess for receiving automated handling equipment for supporting the tray.