Bottle Tray Stacking Structure for Stable Pallet-Free Transport
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Solution Overview
Problem
Conventional pallets and slip sheets are inefficient for transporting and storing bottled water due to instability, damage to bottles, high costs from securing means, difficulty in automated loading, and unsuitability for display, especially causing cap breakage and aesthetic issues with wood pallets.
Innovation Solution
A tray system comprising stacking units with upper and lower receptacles aligned coaxially, featuring a frustoconical-shaped enclosure and cushioned rim to distribute load, allowing secure vertical stacking without straps or plastic wrap, and a pallet for supporting trays, facilitating automated loading and aesthetically pleasing display.
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 bottles become unstable and prone to tipping over and rolling
Solution Approach 1:
The system divides bottles into individual compartments within a rigid tray, with each tray holding a specific number of bottles in fixed positions. This segmentation prevents bottles from moving relative to each other while maintaining bulk transport capacity through stacking multiple trays vertically.
Solution Approach 2:
Trays are designed to nest within each other when empty, and multiple loaded trays stack vertically to form stable columns. The trays feature interlocking elements that allow them to nest securely, maximizing space utilization during transport while maintaining stability.
2Stability of the object's composition
If bottles are secured on pallets using straps or plastic film, then bottles are prevented from shifting, but time and cost increase
Solution Approach 1:
The rigid tray structure provides built-in bottle retention through its molded compartments and rim design, eliminating the need for separate securing mechanisms. Bottles are held in place by the tray's geometric constraints rather than external fastening systems, reducing both time and cost.
Solution Approach 2:
The bottle-holding function and the securing function are merged into a single integrated tray structure. The tray simultaneously provides support, positioning, and retention through its design features, eliminating the need for separate straps or plastic film securing systems.
3Quantity of substance
If bottles are stacked on traditional pallets, then bulk transport is achieved, but cap breakage occurs due to enormous load on spouts and caps
Solution Approach 1:
The tray design provides localized support at critical points, specifically distributing weight across the bottle body rather than concentrating load on the cap and spout. The compartment structure and rim geometry create multiple contact points that spread the mechanical load, protecting vulnerable areas.
Solution Approach 2:
The rigid tray structure is designed to absorb and distribute mechanical loads before they can concentrate on bottle caps. The tray's structural integrity and geometric design provide preemptive protection against cap breakage by creating a load-distributing framework.
4Quantity of substance
If wood pallets are used for bottle transport, then bulk shipping is enabled, but aesthetic appearance deteriorates due to broken planks, popped nails, and splintered surfaces
Solution Approach 1:
The system uses durable, reusable rigid trays made from materials that maintain their appearance over time, replacing the need for aesthetic wood pallets. These trays can be repeatedly used for both transport and display without deteriorating in appearance.
Solution Approach 2:
The rigid trays are designed to serve dual functions: bulk transport and aesthetic display. The same tray structure that enables efficient bottle stacking also provides a clean, professional appearance suitable for customer-facing displays, eliminating the need for separate transport and display equipment.
5Quantity of substance
If conventional pallets and slip sheets are used, then bottles can be transported, but automated loading becomes extremely difficult due to lack of target areas
Solution Approach 1:
The tray divides the loading surface into discrete, clearly defined compartments with specific geometric features. Each compartment serves as a precise target location for automated placement, making it easy for robotic systems to identify and deposit bottles in the correct positions.
Solution Approach 2:
The tray incorporates visual features such as contrasting colors, reflective surfaces, or geometric patterns on the loading surface that are detectable by automated vision systems. These features provide clear visual targets that guide automated loading equipment in positioning bottles accurately.
Data Source
AI summary
A tray system (100) includes a first tray (200) having a plurality of stacking units. Each stacking unit forms a lower receptacle (220) for receiving a neck portion of a first bottle, and an upper receptacle (240) for receiving a base portion of a second bottle to be stacked above the first bottle. The lower receptacle has a first end (222), a second end (224) opposite the first end, and a sidewall (226) connecting the first end with the second end. The first end forms an opening (228) for receiving a neck of a bottle into the lower receptacle. The tray system may also include a second tray (300) and a pallet (400).