IBC Bottle and Pallet Structure for Crack-Resistant Stacking
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Solution Overview
Problem
Existing IBC systems face issues with cracking and deformation due to metallic reinforcement structures, which add expense and compromise the internal storage volume, leading to material loss and handling difficulties.
Innovation Solution
A molded bottle design with varying thicknesses, featuring support columns thicker than sidewalls and ribs, and a pallet system for secure stacking and handling, reducing overall weight while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic reinforcement structures are added to IBCs, then strength and durability are improved, but device complexity and cost increase
Solution Approach 1:
The patent removes the metallic reinforcement structure from the IBC design, relying instead on the inherent strength of the molded bottle and pallet combination. This extraction eliminates the complex metal framework while maintaining structural integrity through optimized plastic bottle and pallet design.
Solution Approach 2:
The patent employs composite material strategies by combining the molded bottle with the pallet in an integrated system designed to work together. The bottle and pallet are engineered as complementary components where the bottle's structural features (columns, ribs, walls) work in conjunction with the pallet's support structure to achieve the required strength without metal reinforcements.
2Reliability
If metallic reinforcement structures are added to IBCs, then durability is improved, but manufacturing cost increases
Solution Approach 1:
The patent eliminates the expensive metallic reinforcement structures, replacing them with an optimized molded bottle and pallet system. This removal of metal components significantly reduces manufacturing costs while maintaining durability through the engineered plastic structure and pallet support.
Solution Approach 2:
The patent changes the material parameters by transitioning from metal reinforcement to plastic construction with optimized wall and column thicknesses. This parameter change reduces material costs and manufacturing complexity while achieving the required durability through proper structural design of the bottle and pallet components.
3Productivity
If IBCs are designed for close packing, then storage efficiency is improved, but bottle deformation occurs under stacking loads
Solution Approach 1:
The patent incorporates preliminary structural reinforcements during bottle manufacturing, including vertically extending columns and horizontally extending ribs positioned to preemptively support stacking loads. These features are built into the bottle structure before use, enabling it to withstand the forces of close packing and vertical stacking without deformation.
Solution Approach 2:
The patent addresses deformation by adding structural elements in multiple dimensions - vertical columns extending from the base and horizontal ribs extending between columns. This multi-dimensional reinforcement strategy distributes stacking loads across the bottle structure, preventing deformation while maintaining close-packing capability.
4Area of stationary object
If IBCs are designed for close packing, then space utilization is improved, but handling in confined spaces becomes difficult
Solution Approach 1:
The patent divides the IBC system into separable components - the molded bottle and the pallet - which can be independently handled. The pallet serves as a handling interface that can be engaged by forklifts and other equipment, allowing the bottle to be moved as a complete unit without requiring direct manipulation of the bottle itself in confined spaces.
Solution Approach 2:
The patent introduces the pallet as an intermediary component between the bottle and handling equipment. The pallet provides external engagement surfaces for forklifts and other material handling devices, enabling easy manipulation and movement of the IBC system without requiring direct access to or manipulation of the bottle in confined spaces.
Data Source
AI summary
An intermediate bulk container system includes a molded bottle and a pallet. The molded bottle includes a bottom wall and a top wall opposite the bottom wall. A plurality of support columns extend vertically from the bottom wall and define a column thickness. A plurality of sidewalls extending vertically between the bottom wall and the top wall and horizontally between the support columns. The sidewalls define a sidewall thickness that is less than the column thickness. The molded bottle further includes a band or belt that wraps around the molded bottle, and the band is formed of a plurality of ribs. Each of the plurality of ribs protrudes outward from one of the plurality of sidewalls and extends between a pair of the plurality of columns, wherein each of the plurality of ribs defines a rib thickness that is less than the column thickness.