Horizontal Egg Container Stacking for Shipping Stability
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Solution Overview
Problem
Existing egg containers face challenges in optimizing manufacturing, shipping, and use, particularly in protecting fragile items like eggs during transportation and storage, while being cost-effective and allowing for easy inspection.
Innovation Solution
The solution involves a packaging configuration of thermoformed polymer containers with hinged portions that can be stacked efficiently, using support panels and corner members to form stable bundles, allowing for horizontal stacking and easy handling, and optionally wrapping with plastic film for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If containers are stacked vertically for shipping, then shipping space utilization improves, but container stability and protection of frangible objects deteriorates
Solution Approach 1:
The patent transitions from vertical stacking to horizontal stacking of containers within a package. Containers are arranged side-by-side on a base panel rather than stacked vertically, fundamentally changing the stacking dimension. This horizontal arrangement maintains high space utilization while providing superior stability and protection for frangible objects during shipping.
2Ease of manufacture
If containers are made thin and lightweight, then manufacturing cost and shipping efficiency improve, but structural strength and protection capability deteriorates
Solution Approach 1:
The patent combines multiple thin container walls through horizontal stacking and interlocking arrangements. While individual containers remain thin-walled for cost-effectiveness, the collective structure of multiple stacked containers creates enhanced structural strength. The interlocking mechanism and distributed loading across multiple containers provide protection equivalent to or greater than single thick-walled containers.
3Ease of operation
If containers are designed for individual use, then ease of use improves, but shipping efficiency and space utilization deteriorates
Solution Approach 1:
The patent divides a large bulk shipping container into multiple smaller, individually usable containers. Each small container maintains its own hinged lid and can be opened independently, preserving ease of use. Meanwhile, these individual containers are designed to nest or stack horizontally within a larger package, achieving high shipping efficiency and space utilization during transportation.
Data Source
AI summary
Package includes stacks of empty containers matingly stacked, panels each having a main surface with peripheral walls, and support members. A first level includes a first panel, one or more stacks of egg containers laid horizontally on the main surface of the first panels within the peripheral walls, and said support members extending from the first panel to a top of the first level. A second level includes a second panel laid on the first level in contact with the support members, one or more stacks of containers laid horizontally on a surface of the second panel within the peripheral walls, and support members extending from the second panel to a top of the second level. A panel is disposed on an uppermost level and having its peripheral walls covering a top of the sides of the uppermost level and in contact with the support members of the uppermost level.