Container Corner Protector with Angled Reception Surface
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Solution Overview
Problem
Existing containers designed for transporting plate-shaped objects like display panels are prone to breakage when fewer panels are housed, due to snagging on corner protectors, which complicates robot-based automation and increases costs for custom containers.
Innovation Solution
A container with corner protectors featuring a second reception surface that tilts inward at an angle less than 90 degrees and has an evacuation portion where the distance between the surface and the side increases towards the bottom, reducing snagging risks and accommodating fewer panels without breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the reception surface is at a 90° angle to the container's bottom surface, then the container structure is simple and manufacturing is easy, but the panel corner gets snagged when the panel is slanted, causing breakage
Solution Approach 1:
The patent changes the geometric parameter of the reception surface from a 90° angle to an angled surface (with an angle θ between 45° and 90° relative to the bottom surface). This parameter change allows the reception surface to accommodate slanted panels without snagging the corners, thereby improving reliability while maintaining reasonable manufacturing simplicity.
2Productivity
If the container is designed for a predetermined number of display panels, then mass production efficiency is high, but housing fewer panels produces excess space and increases the risk of panel sway and breakage
Solution Approach 1:
The patent introduces a movable support member that can be adjusted to fill excess space in the container. This dynamic adjustment capability allows the container to securely hold a variable number of panels, preventing sway and breakage during transport while maintaining the productivity benefits of standardized container designs.
3Reliability
If corner protectors are used to protect panel corners, then panel breakage during insertion is prevented, but the panel corner gets snagged on the protector during removal, causing breakage or reducing work efficiency
Solution Approach 1:
The patent employs a movable support member that can dynamically adjust its position. During panel insertion, the support member provides corner protection. During panel removal, the support member can be retracted or adjusted to eliminate snagging, thereby maintaining both reliability and productivity.
4Reliability
If buffer material is filled in excess space, then panel sway is reduced, but panels may bound due to sway and still get snagged on the reception surface at their corners
Solution Approach 1:
The patent changes the fundamental parameter of the reception surface angle to prevent snagging at its source. This eliminates the need for additional buffer materials to prevent snagging, reducing device complexity while maintaining reliability. The angled surface passively prevents corner snagging regardless of panel position or sway.
Data Source
AI summary
A container includes: a storage member having a bottom-surface member and a side-surface member; and two protectors disposed at two corners adjacent to each other, the two corners belonging to four corners of a storage space. Each of the two protectors has a support portion detachably fitted in a corresponding one of two cuts, a first reception portion having a first reception surface facing an end surface of a housed object, and a second reception portion having a second reception surface facing an end surface of the housed object. The first and/or second reception portion is integral with the support portion. The second reception portion has, in at least a part adjacent to a bottom surface, an evacuation portion in which a distance between the second reception surface and a side surface of the side-surface member facing the second reception surface increases along with approach to the bottom surface.