Inside-Taper Corner Post Tray for Stacked Container Stability
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Solution Overview
Problem
Conventional cellulose-based containers lack effective corner stacking strength and telescoping prevention when stacked vertically, leading to instability and potential collapse.
Innovation Solution
A single-piece foldable container blank made from cellulose-based materials, featuring an inside taper design in the panels that creates a smaller open top than the bottom, along with corner assembly panels and rollover panels that interlock without the need for adhesives, enhancing corner and lateral strength and preventing telescoping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional cellulose-based containers are stacked vertically, then storage efficiency is improved, but corner stacking strength is insufficient leading to instability and potential collapse
Solution Approach 1:
The corner assembly is divided into multiple panels (first corner assembly panel, second corner assembly panel, third corner assembly panel) that can be separately formed and then interlocked, allowing each panel to contribute to the overall stacking strength while maintaining manufacturing efficiency
Solution Approach 2:
The corner assembly panels are designed to nest within each other through interlocking relationships, where the first corner assembly panel interacts with the second, which interacts with the third, creating a nested structure that distributes stacking loads and enhances corner strength
2Productivity
If conventional containers are stacked vertically, then storage efficiency is improved, but telescoping occurs leading to instability
Solution Approach 1:
The container employs an inside taper design where the top opening is smaller than the bottom base, creating an asymmetric geometry that prevents telescoping when containers are stacked vertically, as the narrower top cannot fit over the wider bottom of adjacent containers
Solution Approach 2:
The inside taper introduces a dimensional change in the vertical axis, transitioning from a cylindrical/square profile at the bottom to a smaller profile at the top, creating mechanical interference that prevents telescoping motion between stacked containers
3Strength
If adhesives are used to join container panels, then structural integrity is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The corner assembly panels are designed to self-lock and interlock through their geometric configurations, where the panels automatically secure to each other through friction and mechanical interference, eliminating the need for external adhesives or fasteners
Solution Approach 2:
The patent replaces the chemical bonding system (adhesives) with a purely mechanical interlocking system, where the corner assembly panels use geometric features, friction, and mechanical interference to achieve structural integrity without chemical bonds
Data Source
AI summary
The embodiments of the present invention provide a blank foldable material that may be configured to form a container. When formed, the container is self-locking and includes a rollover panel assemblies formed by spaced apart fold lines that forms bearing surfaces for vertically stacked containers. The container includes a inside taper that functions to prevent telescoping of vertically stacked container, and to hold the various corner panels in their proper location. The blank is configured to form a container that includes corners having multiple thicknesses for strength and stability. The container is self locking, easy us manufacture yet high strength.