Diagonal Pallet Packaging for Liquid Containers
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Solution Overview
Problem
Conventional packaging methods for liquid containers, such as shrink film wrapping, are inefficient in terms of space usage and costly due to the need for pre-stretching and heating the film, and often require additional fastening means to secure the containers, leading to wasted space and increased material costs when stacking on pallets.
Innovation Solution
A large container pallet design featuring diagonal bundles of containers, where at least two layers of packs are arranged one above the other, with each layer comprising diagonal packs that form a hexagonal close pack, supported by an intermediate layer and secured with a banderole or tray-like holding means, allowing for increased stability and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional shrink film packaging is used to bundle containers, then the containers are securely held together, but the packaging cost increases due to expensive film materials and the need for pre-stretching and heating processes
Solution Approach 1:
The invention extracts and eliminates the shrink film packaging process entirely. Instead of using expensive thermoplastic shrink film that requires pre-stretching and heating, the patent uses a paperboard-based packaging structure with integrated holding elements that secure containers through mechanical interlocking and adhesive bonding, thereby removing the need for costly film materials and thermal processing equipment
Solution Approach 2:
The invention replaces expensive, reusable shrink film with inexpensive, disposable paperboard materials. The paperboard packaging units are designed to be single-use, eliminating the need for costly film materials and the energy-intensive heating processes required to activate shrink film, while still providing adequate container securing
2Ease of manufacture
If containers are arranged in conventional rectangular packs, then the packaging structure is simple, but space is wasted on pallet edges when stacking, requiring free space to prevent overhanging
Solution Approach 1:
The invention transitions from symmetric rectangular packaging arrangements to asymmetric diagonal arrangements. The packaging units are configured with irregular shapes and diagonal orientations that allow them to nest together more efficiently on pallets, eliminating wasted edge space and preventing container overhanging without requiring additional free space margins
Solution Approach 2:
The invention introduces diagonal orientation as a new dimensional arrangement approach. Instead of conventional horizontal or vertical stacking, the packaging units are arranged at diagonal angles, creating a more space-efficient three-dimensional configuration on the pallet that maximizes surface area utilization and eliminates edge waste
3Reliability
If additional fastening means such as adhesives or bottle carriers are used to secure containers, then the containers are held more securely, but the device complexity and material costs increase
Solution Approach 1:
The invention merges the functions of container holding, structural support, and fastening into a single integrated paperboard packaging unit. The holding elements are formed as integral parts of the paperboard structure itself, eliminating the need for separate adhesives, bottle carriers, or other additional fastening components, thereby reducing device complexity while maintaining securing reliability
Data Source
Figure 1a~1c
Figure 2a~2c
Figure 3a~3c
AI summary
An even-numbered group of e.g. six plastic bottles (20) is arranged in two transposed rows side-by-side forming a parallelogram array as seen in plan view. Each row has the same number of bottles. The group of bottles is retained as a group by a belt or ring strap.