Caseless Tier Sheet Ribs for Dairy Container Stability
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Solution Overview
Problem
Existing solutions for stacking and transporting dairy containers, such as milk jugs, lack stability and efficiency, particularly for 'caseless' designs, and do not allow for easy access or space optimization during storage and shipping.
Innovation Solution
The use of tier sheets with a support surface and downward protruding walls or ribs to create recesses for container support, allowing for stable stacking and efficient use of space, with options for injection molding or thermoforming to accommodate different container types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional milk jugs are shipped in crates, then they are protected during transport, but the crates take up excessive space and are difficult to return and reuse
Solution Approach 1:
The invention extracts the essential protective function from traditional bulky crates and concentrates it into a compact tier sheet structure. The tier sheet removes unnecessary packaging volume while maintaining protection through its optimized rib and recess design that fits precisely around container dimensions.
Solution Approach 2:
The tier sheet is designed to be easily discarded after use or recovered for reuse in a compact form. Unlike traditional crates that are difficult to return and reuse, the tier sheet can be flattened and stacked efficiently, making the recovery and reuse process practical and space-efficient.
2Volume of moving object
If caseless dairy containers are stacked without tier sheets, then space is maximized, but stability is insufficient
Solution Approach 1:
The tier sheet is designed with pre-formed recesses and ribs that are specifically shaped to match the dimensions of caseless dairy containers. This preliminary configuration ensures that when containers are placed in the recesses, they are automatically positioned and stabilized without requiring additional adjustment or support structures.
3Adaptability or versatility
If tier sheets are designed for traditional milk jugs with necks, then they accommodate the cap structure, but they do not optimize space for caseless designs
Solution Approach 1:
The tier sheet employs local quality variations through its rib structure, where different regions have different heights and configurations. The ribs are strategically positioned to provide support at critical points for various container types, allowing the same tier sheet design to accommodate both traditional jugs with necks and caseless containers with different upper wall configurations.
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
Provides increased stability and space efficiency for dairy containers during storage and shipping, enabling easy access and reuse of the tier sheets, while allowing for compact and secure stacking on pallets.
Implementation Method 1
The disclosed example injection molded tier sheet is specifically designed for the caseless dairy containers described above
Implementation Method 2
the tier sheet is a single thermoformed sheet and includes a plurality of upper recesses formed in the deck
Data Source
AI summary
A tier sheet includes a deck having a support surface. A plurality of walls extend downward to define lower recesses for receiving the upper ends of containers therebelow. In one embodiment, the tier sheet is a single thermoformed sheet and includes a plurality of upper recesses formed in the deck, each upper recess defined between an outer wall and a column. In another embodiment, the tier sheet is injection molded.