Collapsible Bulk Bin Container with Integrated Pallet Runners
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Solution Overview
Problem
Conventional corrugated paperboard containers are heavy, expensive, and difficult to transport and recycle, and integrated container and pallet systems face issues with shipping in a knocked-down state and assembly at the destination, while also requiring wooden pallets that are costly and hard to handle.
Innovation Solution
A collapsible bulk bin container system comprising a foldable tray with pallet runner sleeves, a telescopically enclosing lid, and a foldable side wall body made from corrugated paperboard, allowing for easy assembly and disassembly, efficient storage, and international shipping without lumber treatment codes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional corrugated paperboard containers are used, then they provide basic storage functionality, but they are heavy, expensive, and difficult to transport and recycle
Solution Approach 1:
The container is divided into separate modular components including a collapsible body, a telescopic lid, and integrated pallet runners. These segments can be assembled and disassembled, allowing the container to be collapsed into a compact form for economical transport and storage while providing full functionality when assembled.
Solution Approach 2:
The container transitions from a static structure to a dynamic, collapsible system. The body can be collapsed into a compact state for transport, then easily assembled at the destination. The telescopic lid similarly transitions between extended and retracted positions, enabling space-efficient handling throughout the supply chain.
2Stability of the object's composition
If integrated container and pallet systems are used, then handling stability is improved, but the ability to ship in a knocked-down state is compromised
Solution Approach 1:
The integrated pallet and container body are designed as separate but compatible components. The pallet runners are integrated with the container body structure, allowing them to function as a unified system when assembled, while remaining separable for collapsed shipping configurations.
Solution Approach 2:
The container body, pallet runners, and lid are designed to nest within each other when collapsed. The compact nested configuration minimizes shipping volume while maintaining the structural integrity and stability of the complete system when assembled at the destination.
3Strength
If wooden pallets are used, then strong support is provided, but they are heavy, expensive and difficult to transport or recycle
Solution Approach 1:
The material composition is changed from traditional wood to corrugated paperboard. This parameter change maintains the necessary structural strength and support capabilities through optimized paperboard construction, while dramatically improving recyclability and eliminating the need for wood treatment codes for international shipping.
Solution Approach 2:
The pallet and container system uses composite corrugated paperboard construction that combines multiple layers and structural elements to achieve the required strength. This composite approach provides equivalent or superior support to wooden pallets while being fully recyclable and free from lumber treatment restrictions.
4Ease of operation
If containers are stacked on pallets without fastening, then ease of loading is maintained, but the containers may become displaced or fall off during handling
Solution Approach 1:
The pallet and container body are merged into an integrated system where the pallet runners are built into the container structure. This merging provides inherent stability and prevents displacement during handling, while maintaining ease of loading through the integrated design that eliminates separate fastening operations.
Data Source
AI summary
A collapsible shipping container is capable of configured from a collapsed position for storage and transportation to a constructed position for containment of articles therein and back again to the collapsed position after use. The collapsible shipping container comprises a foldable tray having at least two pallet runner sleeves spaced apart from one another and each of which being formed on respective opposed lateral edges of the foldable tray. A plurality of elongated pallet runners each of which having an inner support structure integrally formed thereto. The plurality of elongated pallet runners each of which is adapted to be inserted into each of the respective plurality of pallet runner sleeves. A foldable side wall body is adapted to rest upon the foldable tray to form an interior space to receive a plurality of articles. The foldable side wall body comprises end walls, side walls, and side body flaps to form an enclosed bottom thereof. Each of the end walls includes an articulation fold formed therein so that during the collapsed position, the articulation folds move toward the interior space and during the constructed position, the articulation folds move away from the interior space. A lid is configured to telescopically enclosing the collapsible shipping container.