Blank Assembly for Reinforced Stackable Tray Container
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Solution Overview
Problem
Existing tray containers have limitations such as solid end walls that prevent viewing and access to products, require separate shipping pads, and are not easily convertible to a knocked-down flat configuration for efficient storage and shipping.
Innovation Solution
A blank assembly for forming a reinforced tray container with removable pad panels, auto-forming bottom, and side inserts that allow for nesting and easy assembly into a stackable, erect configuration, eliminating the need for additional shipping pads and enabling 360° access to products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid end walls are used in tray containers, then structural strength is improved, but viewing and access to products is prevented
Solution Approach 1:
The end wall is segmented into a solid portion and a removable pad panel portion. The pad panel can be removed to provide access and viewing, while the solid portion maintains structural strength. This segmentation allows the wall to serve both structural and access functions at different times.
Solution Approach 2:
The end wall transitions from a static solid structure to a dynamic structure where the pad panel can be removed. This creates a variable configuration that adapts between providing structural support and providing access/viewing capabilities based on operational needs.
2Reliability
If separate shipping pads are used, then product protection during shipping is improved, but device complexity and assembly steps are increased
Solution Approach 1:
The shipping pad function is merged with the end wall structure itself. The pad panel is integrated as part of the end wall assembly, eliminating the need for separate shipping pads and their associated attachment steps. The integrated pad panel provides both structural support and product protection functions.
Solution Approach 2:
The end wall pad panel serves multiple functions: it provides structural support to the container, protects products during shipping, and when removed, creates an opening for product access. This multi-functionality replaces what would otherwise require separate components.
3Ease of manufacture
If traditional tray containers are used, then manufacturing simplicity is maintained, but storage efficiency and shipping cost are worsened due to inability to knock-down flat
Solution Approach 1:
The bottom wall is designed with dynamic folding capability, allowing it to transition between an erect configuration for use and a folded/knocked-down configuration for storage. This dynamic structure enables the container to be compacted to a fraction of its operational volume without complicating the manufacturing process.
Solution Approach 2:
The bottom wall is segmented into multiple foldable sections that can collapse together. This segmentation allows the bottom to be knocked down flat while maintaining the integrity and simplicity of the overall container structure during manufacturing.
4Strength
If reinforced walls are added for stacking, then stackability and strength are improved, but device complexity and material usage are increased
Solution Approach 1:
The reinforcing function is merged with the existing end wall and side wall structures. The pad panels and solid wall portions are integrated to provide both structural support and stacking strength without requiring separate reinforcement components. The structure uses its own walls to provide the necessary strength for stacking.
Data Source
AI summary
A blank assembly includes a tray blank having a first end panel assembly, a first side panel assembly, a second end panel assembly, and a second side panel assembly in series. Each panel assembly includes a removable pad panel. The tray blank further includes a bottom panel extending from each panel assembly at a fold line. The blank assembly further includes a first side insert blank configured to couple to the first side panel assembly. The first side insert blank having a removable pad panel configured to at least partially align with the removable pad panel of the first side panel assembly. A second side insert blank is configured to couple to the second side panel assembly. The second side insert blank includes a removable pad panel configured to at least partially align with the removable pad panel of the second side panel assembly.