Modular Corrugated Bin System with Adjustable Height Extensions
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Solution Overview
Problem
Existing polymer bins are limited in size and height, making them inflexible for custom use, expensive to tool, and difficult to manufacture in taller sizes, leading to inefficiencies in storage and transportation, as well as obsolescence when components change.
Innovation Solution
A selectively configurable bin made from corrugated material with a monolithic base and adjustable corner posts, allowing for customizable height and lightweight design, featuring a channel system with ribs and protrusions for secure stacking and easy assembly/disassembly, and handles for ergonomic handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If polymer bins are made in limited standard sizes to fit pallet footprints, then shipping efficiency is improved, but bin versatility and adaptability to different components deteriorates
Solution Approach 1:
The bin is divided into modular components: a base unit with standardized footprint and multiple interchangeable height extensions. This segmentation allows the same base to accommodate different heights (11 inches, 23 inches, etc.) by adding or removing extension sections, thereby maintaining shipping efficiency while greatly increasing versatility for different component sizes.
Solution Approach 2:
The bin height is made dynamic and adjustable rather than fixed. Height extensions can be added or removed based on the specific component storage needs, allowing the bin to adapt to different heights while maintaining the same standardized base footprint for efficient pallet loading.
2Productivity
If taller polymer bins are manufactured to reduce stacking layers, then pallet load height efficiency is improved, but manufacturing difficulty and tooling complexity worsens
Solution Approach 1:
Instead of manufacturing single tall bins which are difficult to tool, the bin is segmented into a standardized base unit and separate height extension sections. Each section can be manufactured using standard tooling, avoiding the need for expensive and complex tooling for tall single-piece bins, while still achieving the desired pallet load height efficiency when sections are stacked.
Solution Approach 2:
Multiple standardized sections are combined through stacking to achieve tall bin configurations. The base unit stacks with height extensions using standardized connection features, effectively merging multiple easily-manufactured components into a tall bin assembly without requiring complex tooling for the entire height.
3Adaptability or versatility
If custom-sized bins are made by cutting and welding polymer bins, then bin customization is improved, but bin weight and transportation cost worsens
Solution Approach 1:
The bin is designed as segmented modular units that can be configured to different heights by adding or removing standard extension sections. This provides customization without requiring cutting and welding, and the modular design optimizes material usage to reduce weight compared to welded custom bins.
Solution Approach 2:
Bin customization is achieved by changing the height parameter through adding or removing standard extension sections rather than cutting and welding. This parameter change approach maintains optimal wall thickness and material distribution, resulting in lighter bins compared to welded custom-sized bins where material must be added or removed through fabrication.
4Productivity
If polymer bins are made with standardized heights for pallet stacking, then stacking efficiency is improved, but bin adaptability to different component heights deteriorates
Solution Approach 1:
The bin system is segmented into a standardized base unit and interchangeable height extensions. The base unit maintains standardized dimensions for efficient pallet stacking, while height extensions provide adaptability to different component heights. This segmentation allows the same base to work with multiple extension heights, combining stacking efficiency with adaptability.
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
Enables the creation of custom-sized bins that are lighter, cheaper to transport, and more versatile in stacking configurations, maximizing pallet load capacity and reducing waste by repurposing unwanted or obsolete bins.
Implementation Method 1
The corrugated material is configured to plastically deform in compression around its perimeter
Implementation Method 2
protrusion features are formed lining inside of bin wall channel to pinch/secure the wall in place
Implementation Method 3
Male locating post with a flexible clip feature lock corner post in position and unlocking for disassembly of bin
Data Source
AI summary
Engineered handheld bin system constructed of modular components creating custom heights and increased interior volume greater than known handheld plastic containers. The bin includes a base, a frame, four corner members and a wall member having a plurality of side panels. In one embodiment, the four corner members interlockably couple the frame and the base. In one embodiment, the base includes a base frame defining a channel to selectively couple to the bottom edge of the wall member and the frame defines a wall member accepting slot to engage and compress a portion of the top edge of the wall member.