Hinged Flat-Pack Insulated Shipping Container to Reduce Assembly Time
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Solution Overview
Problem
Passive thermally insulated shipping containers require complex assembly and increased pack-out times due to numerous components, which can lead to errors and inefficiencies, especially in large shipments, and are prone to distortion during handling, potentially disrupting the thermal barrier.
Innovation Solution
A thermally insulated shipping container design featuring hinged side outer walls that form a U-shaped configuration for self-support and ease of assembly, reducing the number of components to unpack and assemble, and utilizing a robust structure that can be flat-packed for efficient transportation and assembly, with preassembled components to simplify the process and enhance handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If passive shippers are delivered flat packed to reduce in-bound delivery costs, then storage and transportation efficiency are improved, but pack out times significantly increase
Solution Approach 1:
The hinge connections are pre-assembled during manufacturing, allowing the side outer walls to be preliminarily configured in a connected state. This preliminary action reduces the number of assembly steps required during pack out, as the walls only need to be unfolded and positioned rather than completely assembled from separate components.
Solution Approach 2:
The outer wall is segmented into multiple panels (front outer wall, rear outer wall, side outer walls) that are connected by hinges. This segmentation allows each panel to be independently handled and positioned during assembly, simplifying the pack out process while maintaining the ability to fold flat for storage.
2Strength
If passive shippers have multiple components to form the complete structure, then structural integrity is improved, but assembly complexity and error potential increase
Solution Approach 1:
Multiple outer wall panels are merged into a single assembled structure through hinge connections. The front outer wall, rear outer wall, and side outer walls are combined to form the complete outer structure, reducing the number of separate components that need to be handled during assembly while maintaining structural integrity.
Solution Approach 2:
The hinge connections between wall panels are pre-assembled during manufacturing, preliminarily combining multiple components into a partially assembled unit. This reduces the complexity of final assembly by eliminating the need to connect separate panels during pack out, while still providing the structural benefits of multiple integrated components.
3Stability of the object's composition
If passive shippers are designed for flat packing, then storage efficiency is improved, but robustness against handling damage during assembly decreases
Solution Approach 1:
The outer wall structure is designed to be dynamic, transitioning between a folded flat state for storage and an unfolded three-dimensional state for use. The hinge connections enable this dynamic transformation, allowing the structure to be compact during storage yet robust when assembled and in use.
Solution Approach 2:
The hinge connections are pre-assembled and reinforced during manufacturing, preliminarily strengthening the joints before they undergo repeated folding and unfolding. This preliminary reinforcement ensures that the connection points can withstand handling stresses during both flat packing and assembly operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design significantly reduces assembly time and errors, increases the container's robustness against handling damage, and allows for efficient flat-packing and stacking, enhancing the reliability and cost-effectiveness of temperature-controlled shipments.
Implementation Method 1
a portion of each of the two side outer walls is hinged at one end to a respective end of one of the front or rear outer walls
Implementation Method 2
a thermally insulated shipping container
Implementation Method 3
This relies on cool blocks (which may be frozen or chilled) being placed around the product to maintain the product within a desired temperature range
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A thermally insulated shipping container 1 comprises an inner structure including an inner base 3, a front inner wall, a rear inner wall opposed to the front inner wall,a pair of opposed side inner walls each extending between the front and rear inner walls and an inner lid 6, 7; an outer structure including an outer base 3, a front outer wall, a rear outer wall opposed to the front inner wall, two side outer walls each extending between the front and rear outer walls and an outer lid; and a cavity extending at least between the inner and outer walls, the cavity being arranged to receive a plurality of cool packs 18; wherein the container 1, when empty, is arranged to be transported disassembled in a flat packed state prior to being assembled for use, and wherein a portion of each of the two side outer walls is hinged at one end to a respective end of one of the front or rear outer walls. The container 1 has been arranged to minimise pack out time