Foldable Tray Container with Tab-and-Slot Assembly
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Solution Overview
Problem
Existing container manufacturing processes require excessive material and labor to prepare container blanks, leading to inefficiencies in production and versatility.
Innovation Solution
A one-piece foldable container blank design featuring hingedly joined panels with slots and tabs, allowing for easy assembly into a tray form with customizable structures for various item storage, such as a rectangular base, sidewalls, and a curved top portion with an outer strip and tab system for stabilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional container manufacturing processes are used, then containers can be produced, but excessive material and labor are required to prepare container blanks
Solution Approach 1:
The container blank is divided into multiple hingedly joined panels (first panel, second panel, third panel, fourth panel, fifth panel, sixth panel) that can be separately formed and then assembled together, reducing the complexity of preparing a single large blank and allowing more efficient material utilization
Solution Approach 2:
The sixth panel with tab is inserted into the slot formed by the first panel and fifth panel, creating a nested assembly structure that stabilizes the container blank and eliminates the need for excessive material to maintain structural integrity during preparation
2Productivity
If traditional container manufacturing processes are used, then containers can be produced, but excessive labor is required to prepare container blanks
Solution Approach 1:
The container blank is pre-formed with hingedly joined panels, slots, and tabs in a flat configuration before assembly, allowing rapid transformation into the final three-dimensional container shape without requiring time-consuming shaping operations during production
Solution Approach 2:
The hingedly joined panels automatically align and connect to form the container structure when assembled, with the tab inserting into the slot to self-stabilize the configuration, eliminating the need for complex fastening operations and reducing labor time
3Ease of manufacture
If a one-piece foldable container blank is used, then material usage and labor are reduced, but structural stability must be maintained
Solution Approach 1:
The third panel has a first curved edge and the fourth panel has a second curved edge, creating curved sidewalls that provide structural strength and stability while maintaining the foldable one-piece blank design, allowing the container to resist deformation during use
4Ease of operation
If hingedly joined panels with slots and tabs are used, then assembly is simplified, but manufacturing precision is required for proper fit
Solution Approach 1:
The slot and tab system serves multiple functions: it guides the panels into proper alignment during assembly, provides mechanical interlocking for structural stability, and accommodates minor dimensional variations through the insertion motion, reducing the stringency of precision requirements compared to rigid joining methods
Data Source
AI summary
A tray for holding food or other items is provided. The tray includes a base, a curved top, and an inner space. A one-piece blank to form such a tray is also provided.