Foldable Transport Tray With Integrated Lid And Reinforced Bottom
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Solution Overview
Problem
Existing product transport and storage trays face challenges such as difficulty in folding when empty, lack of reinforcement for stacking, insufficient bottom strength for heavy products, and inadequate protection during transport due to the absence of a built-in lid.
Innovation Solution
A tray design featuring a sheet with oblique folding lines that form sectors for enhanced folding and stacking, reinforced end walls with flaps for improved vertical compression resistance, and a double bottom structure for increased strength, along with a lid function using foldable side flaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcing columns are formed at the corners of the tray, then vertical compression resistance for stacking is improved, but the tray folding operation becomes difficult when empty
Solution Approach 1:
The tray is divided into modular sectors (first sector, second sector, third sector, fourth sector) separated by folding lines, allowing independent folding of each section. This segmentation enables the tray to be collapsed flat for storage while maintaining structural integrity when assembled, resolving the conflict between stacking strength and folding ease.
Solution Approach 2:
The tray structure transitions from a static rigid form to a dynamic collapsible structure through the use of folding lines and movable flaps. The first flaps and second flaps can be folded inward or outward as needed, allowing the tray to adapt between its operational state (with reinforcement) and storage state (fully collapsed), thus enabling both strong stacking and easy folding.
2Strength
If flaps are glued on the side walls for stacking, then stacking capability is improved, but the tray cannot be folded for storage once finished
Solution Approach 1:
The tray employs dynamic folding mechanisms instead of permanent glued connections. The folding lines allow the tray to be assembled and disassembled repeatedly, while the flaps provide temporary reinforcement during stacking operations. This dynamic design enables the tray to maintain stacking capability while remaining foldable for storage, eliminating the need for permanent adhesives.
3Ease of manufacture
If the bottom is a continuous surface of single material thickness, then manufacturing is simplified, but the bottom may not be strong enough to transport products with certain weight
Solution Approach 1:
The bottom is divided into multiple sectors (first sector, second sector, third sector, fourth sector) with folding lines creating a segmented structure. This segmentation allows the bottom to be manufactured from a single sheet of material while creating reinforced zones at the folding lines and joining zones, thereby maintaining manufacturing simplicity while significantly enhancing bottom strength to support heavier products.
4Device complexity
If no built-in lid is provided, then the tray structure is simpler, but products are not fully protected during transport
Solution Approach 1:
The flaps of the tray serve multiple functions: they can be folded inward to form walls for containing products, folded outward to provide reinforcement for stacking, and positioned to create a protective enclosure that functions as a built-in lid. This multi-functionality provides complete product protection during transport without adding separate lid components, thus maintaining structural simplicity while enhancing protection.
5Strength
If double wall is created by crossing layers in end walls for handle reinforcement, then handle strength is improved, but products are exposed to outside through handles and contact with hands
Solution Approach 1:
The end walls are designed with flaps that extend beyond the basic wall plane, creating additional dimensional layers. These flaps can be folded inward to form an inner wall that separates the product from the handle opening, effectively adding a protective barrier in the third dimension. This allows the handle to maintain its strength through layered construction while preventing direct exposure of products to external contact.
Data Source
AI summary
A tray comprises a foldable sheet including: a bottom having a first sector with a folding line that defines a first joining zone, and a second sector joined to the first sector in the first joining zone; end walls each having an interior surface; support surfaces each extending from an end wall, where the support surfaces are oriented to support the weight of another stacked tray; first flaps each extending from a support surface, where each of the first flaps is folded towards an interior of the tray and having a surface facing and separated from the interior surface of an end wall; side walls; and a second flap extending from a side wall. The second flap is placeable a first position on a side wall for reinforcement and in a second position substantially perpendicular to the side walls to serve as a lid.