Dairy Tray Structure for Fork-Tine Access and Nested Stacking
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Solution Overview
Problem
Existing dairy product shipping and storage systems are inefficient, requiring manual handling and stacking of trays, which can be cumbersome and ergonomically challenging, and lack compatibility with automated handling equipment.
Innovation Solution
A tray system with a base featuring offset peripheral portions and column structures that allow for efficient stacking, nesting, and direct handling by fork tines, while accommodating different container sizes with interchangeable trays, enhancing ergonomics and compatibility with conveyance equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If trays are designed for manual handling and stacking, then ease of operation is improved, but compatibility with automated handling equipment deteriorates
Solution Approach 1:
The tray design incorporates features that serve both manual and automated handling functions. The peripheral portion with upward offset provides hand engagement surfaces while simultaneously offering fork tine access points. The base structure with integrated support surfaces and lifting features enables both manual stacking and automated fork lift operation, making the tray universal for multiple handling methods.
2Ease of manufacture
If tray structure is simplified for easy manufacturing, then ease of manufacture is improved, but structural integrity deteriorates
Solution Approach 1:
The tray base is segmented into distinct functional zones: a central portion for support, a peripheral portion for lifting, and integrated column structures. This segmentation allows each zone to be optimized for its specific function while maintaining overall structural integrity. The peripheral portion offset upward from the central portion creates distinct load paths that enhance strength without requiring complex manufacturing.
3Manufacturing precision
If trays are designed with fixed configuration for specific container sizes, then manufacturing precision is improved, but adaptability deteriorates
Solution Approach 1:
The tray system employs nested column structures where upper column portions can contain or be surrounded by lower column portions. This nesting arrangement allows the same tray base to accommodate different container sizes by adjusting which column portions engage with the containers. The peripheral portion offset upward provides a consistent lifting surface while the nested columns offer variable support configurations.
Data Source
AI summary
A tray includes a base having an upper support surface and a central portion extending downward to define a lowermost surface of the tray. The base includes a peripheral portion recessed relative to the central portion. A pair of opposed first walls extend along opposed first edges of the base. A pair of opposed second walls extending along opposed second edges of the base.