Container Stacking Feature with Alignment Structures for Full Nesting
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Solution Overview
Problem
Thin-walled disposable plastic containers are prone to bending, distortion, and crushing, and often fail to fully nest when stacked, leading to instability and increased space usage.
Innovation Solution
The container design incorporates axially-extending alignment structures and stacking features, such as upper and lower shoulders/indents, to enhance structural rigidity and facilitate full nesting, while maintaining a thin wall thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thicker material construction is used to strengthen containers, then container strength is improved, but production costs increase
Solution Approach 1:
The container sidewall is divided into multiple functional zones: thin-walled sections for cost reduction and thick-walled sections at specific locations (shoulders, indents, gripping zones) for strength enhancement. This segmented approach allows optimization of material distribution rather than uniform thickening throughout the entire container.
Solution Approach 2:
Thicker material is applied locally at critical areas where strength is needed most - specifically at the upper and lower shoulders, stacking indents, and gripping zones - while maintaining thin walls in non-critical areas. This local quality enhancement provides targeted strength improvement without overall material increase.
2Productivity
If containers are stacked one on top of the other, then storage efficiency is improved, but containers may not fully nest leading to instability and increased space usage
Solution Approach 1:
The container design incorporates nested stacking features where an upper container nests within a lower container. The upper shoulder of one container fits within the stacking indent of the container below, creating a nested configuration that maximizes space efficiency while maintaining stack stability through proper geometric engagement.
Solution Approach 2:
The stacking features utilize asymmetric geometry with the upper shoulder having a specific profile that complements the asymmetric stacking indent below it. This asymmetric design ensures proper alignment and stable nesting, preventing containers from sticking together or becoming misaligned during stacking operations.
3Adaptability or versatility
If non-round cross-sectional shapes are used for containers, then manufacturing flexibility is improved, but containers fail to fully nest when stacked
Solution Approach 1:
The container cross-section is segmented into a non-round outer shape for manufacturing versatility and stacking features with circular or near-circular profiles at the stacking zones. This segmentation allows the container body to maintain flexible non-round geometries while the stacking interfaces use shapes optimized for full nesting and stable stacking.
Data Source
AI summary
A container having enhanced wall integrity with a rotational element and a stacking feature is provided. The container includes a sidewall having an alignment structure formed along a height of the sidewall and an upper stacking shoulder formed above the alignment structure. The alignment structure is adapted for orienting the container with respect to a second container so that the alignment structures of the containers become parallel with one another and the containers may be fully nested one within the other. The alignment structure can be recessed into the sidewall to form peaks and valleys along an inner surface of the container. The upper stacking feature is formed into the sidewall of the container and includes a radially extending wall portion and an upwardly extending wall portion that together form a stacking corner. The stacking shoulder is provided above the alignment structure facilitates nesting of two containers when stacked together.