Modular Reusable Shipping Crate with Collapsible Interlocking Design
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Solution Overview
Problem
Traditional wood shipping crates are economically inefficient, resource-intensive, environmentally destructive, and lack condition and location monitoring capabilities, making them unsuitable for modern logistics needs, especially for high-tech cargo like data server racks and healthcare devices.
Innovation Solution
A modular, reusable shipping crate system featuring a collapsible interlocking design with a pallet base, enclosure frame, and lid, made from materials like plastics and metal, which includes a condition and location monitoring device for humidity, temperature, tilt, impact, and GPS tracking, allowing for efficient return shipment and versatile cargo handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional wood shipping crates are used, then cargo can be transported, but the crates are heavy and difficult to maneuver
Solution Approach 1:
The crate is divided into separate components: a base unit and removable side wall assemblies. This segmentation allows the side walls to be detached, reducing the weight that must be maneuvered during loading and unloading operations while maintaining full crate functionality when assembled.
Solution Approach 2:
The side wall assemblies are designed with movable and removable characteristics, transitioning from a static rigid structure to a dynamic configurable system. This allows the crate to be reconfigured or partially disassembled for easier handling and reduced maneuvering effort.
2Productivity
If wood shipping crates are used, then cargo can be transported, but they are economically inefficient and resource-intensive
Solution Approach 1:
The modular crate system is designed for repeated use and recovery. Instead of single-use wood crates that are discarded after one shipment, this system allows the base unit and side wall assemblies to be reused across multiple shipping cycles, eliminating material waste and improving economic efficiency through sustainable resource utilization.
Solution Approach 2:
The base unit can accommodate different side wall assemblies to create various crate configurations for different cargo types. This multi-functionality increases shipping productivity by eliminating the need for multiple specialized crates, thereby reducing material consumption and waste.
3Reliability
If traditional wood crates are used, then cargo can be transported, but they lack condition and location monitoring capabilities
Solution Approach 1:
Monitoring devices are integrated into the base unit of the crate system, merging the monitoring function with the existing structural component. This approach adds reliability through condition and location monitoring while minimizing additional complexity by utilizing the base unit as the housing and power source for the monitoring system.
4Volume of moving object
If wood shipping crates are used, then cargo can be transported, but the crates are bulky and occupy large storage space when empty
Solution Approach 1:
By segmenting the crate into a base unit and removable side wall assemblies, the side walls can be detached and stored separately or nested within the base unit. This significantly reduces the volume occupied by empty crates during storage and reverse logistics, improving storage efficiency without compromising the crate's functionality when assembled.
Data Source
AI summary
A system, method, and device for shipping, transporting, storing, and managing logistics of a variety of cargo. A crate is disclosed that allows for easy and inexpensive return shipment (reverse logistics) after use through a collapsible, interlocking system of a pallet base, foldable side wall assemblies, and a lid that can be removably connected to one another. The crate can utilize guide protrusions and corresponding guide recesses to fit the components together. The height of the crate can be increased by additional tiers of side walls. Latch assemblies can be utilized to fasten adjacent components together. The crate may include a tracking or monitoring device that can monitor one or more of humidity, temperature, tilt, impact, vibration, and variety of desired conditions. The system may include Bluetooth beacons on each of the components and a Bluetooth sensor in the monitoring device in the pallet base to monitor disassembled components.