Integrated Damping Tray for Shock-Protected Transport
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Solution Overview
Problem
Conventional transport structures for shock- and moisture-prone items like battery cells require multiple packaging elements made of different materials, leading to complexity in manufacturing and a compromise between damping and rigidity, with elastic materials posing challenges in cleaning and protection against local loads.
Innovation Solution
A one-piece tray design with integrated damping elements between the side wall and receiving area, made of plastic, which absorbs lateral forces and distributes them over a larger area, providing both damping and rigidity, and featuring complementary receiving areas for secure stacking and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple packaging elements made of different materials are used for damping and protection, then damping performance is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple packaging elements (enclosure, insert, and damping elements) into a single integrated tray structure made of plastic. The tray includes an enclosure with integrated damping elements formed between the side wall and the receiving area, eliminating the need for separate foam or cardboard inserts while maintaining both damping performance and structural integrity.
2Strength
If elastic materials are used for damping, then shock protection is improved, but cleaning ease deteriorates
Solution Approach 1:
The patent changes the material parameter from traditional elastic foam materials to plastic material with integrated damping elements. The damping elements are formed as integral parts of the plastic tray structure, providing shock protection through the tray's inherent elasticity while maintaining a smooth, non-porous surface that is easy to clean and sanitize.
3Strength
If elastic materials with high manufacturing tolerances are used, then damping performance is improved, but protection against water and moisture deteriorates
Solution Approach 1:
The patent changes the material from traditional elastic materials with high tolerances to plastic material that can be manufactured with tighter tolerances. The integrated damping elements are formed as precise integral parts of the plastic tray, providing both damping performance and effective sealing against water and moisture penetration.
4Ease of manufacture
If a one-piece design is used, then ease of manufacture is improved, but material selection flexibility deteriorates
Solution Approach 1:
The patent changes the material parameter to plastic, which can be manufactured in a one-piece design using injection molding or similar processes. This material choice enables the production of a complex integrated structure with damping elements, receiving areas, and enclosure all formed as a single piece, simplifying manufacturing while providing sufficient versatility for transport applications.
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 tray effectively absorbs external loads, protects against shocks and moisture, facilitates easy cleaning, and allows secure stacking without material compromise, enhancing handling and protection for transported items.
Implementation Method 1
If the insert is made of an elastic material, it can reduce peak loads, such as shocks or temperature changes, that act on the transport item
Implementation Method 2
damping elements for dampening shocks are provided between a tray side wall and the first receiving area
Implementation Method 3
The distance between the tray side wall and the receiving area allows a limited elastic displacement of the tray side wall in the direction of the receiving area under load
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The disclosure relates to a tray (2), preferably made of plastic, with at least one, preferably centrally arranged, first receiving area (6) open toward a tray top (4) and having at least one first receptacle (8) for at least one transport object (58). Damping elements (14) for dampening impacts, which are formed with the tray (2), are provided between a tray side wall (10) and the receiving area (6), at least in sections, preferably completely surrounding the receiving area (6) in the circumferential direction.