Bottle Tray System with Elastomeric Cushions for Stack Stability
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Solution Overview
Problem
Conventional pallets and slip sheets used for transporting and storing bottled water are unstable, prone to damage, and require additional securing methods, which increase costs and lead to bottle breakage and spillage, while also being unsuitable for automated loading and aesthetically unappealing.
Innovation Solution
A tray system with stacked units that include lower and upper receptacles designed to securely hold bottles vertically, featuring a frustoconical-shaped enclosure and elastomeric cushions to distribute load and prevent scratching, allowing for stable and secure storage and transportation without the need for additional securing methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If bottles are stacked on traditional pallets and slip sheets, then bottles can be transported in bulk, but the stack becomes unstable and bottles are prone to tipping over and rolling
Solution Approach 1:
The system divides the bulk transportation into discrete modular units using trays with multiple receptacles. Each receptacle individually secures a bottle, while the entire tray forms a stable module. This segmentation prevents bottles from tipping and rolling while maintaining bulk transportation capacity through stacking multiple trays.
Solution Approach 2:
The tray system acts as an intermediary between the bottles and the pallet. The tray with its receptacles provides the stabilizing structure, while bottles are secured within the tray rather than directly on the pallet. This intermediary structure eliminates the need for straps or plastic film while maintaining stack stability.
2Reliability
If bottles are secured using straps or plastic film on pallets, then bottle shifting is prevented, but time and cost increase due to additional securing processes
Solution Approach 1:
The tray system is self-securing through its receptacle design. Bottles are held in place by the physical structure of the receptacles and stacking geometry, eliminating the need for external straps or plastic film. This self-service mechanism reduces both time and cost while maintaining reliable bottle security.
3Quantity of substance
If bottles are stacked on pallets with flat surfaces, then bottles can be loaded in bulk, but automated loading becomes difficult due to lack of target areas
Solution Approach 1:
The receptacles provide distinct visual and physical target areas that guide automated placement. Each receptacle's geometry and positioning create clear targets for robotic or automated loading systems, enabling precise bottle placement while maintaining bulk loading capacity.
4Quantity of substance
If bottles are stacked on conventional pallets, then transportation is possible, but the pallets are aesthetically unappealing with broken planks and popped nails
Solution Approach 1:
The system segments the transportation function into reusable trays with uniform, clean receptacles. These modular trays present a neat, consistent appearance suitable for display, while still providing bulk transportation capability. The trays can be stacked and stored efficiently when not in use.
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 tray system provides a stable, secure, and aesthetically pleasing solution for storing and transporting bottles, reducing damage and breakage, facilitating automated loading, and eliminating the need for additional securing materials.
Implementation Method 1
an elastomeric cushion, configured to rest directly on a shoulder portion of a first bottle received in the lower receptacle
Data Source
AI summary
A tray system for display, storage and transportation of bottles includes a first tray having a plurality of stacking units. Each stacking unit can include a lower receptacle for receiving a neck portion of a first bottle. Each stacking unit can also include an upper receptacle for receiving a base portion of a second bottle to be stacked vertically above a first bottle. The lower receptacle can include a first end, a second end opposite the first end, and a sidewall connecting the first end with the second end. The first end forms an opening for receiving a neck of the first bottle into the lower receptacle. The lower receptacle further includes a protective element. The protective element can be attached to the lower receptacle to provide a protective guard between the lower receptacle and a shoulder portion of the first bottle received in the lower receptacle.