Movable Dunnage Supports in Shipping Containers
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Solution Overview
Problem
Existing container designs pose ergonomic challenges for workers, requiring them to walk around or bend to access products, leading to strain and increased risk of injury, and often necessitate multiple containers to accommodate product size and weight, increasing shipping costs.
Innovation Solution
A container with linear tracks and movable padded dunnage supports that allow products to be easily pulled forward for unloading and loaded from a more ergonomic position, reducing the need for workers to stretch or bend, and enabling efficient use of space without requiring multiple containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If products are stored in traditional fixed-position containers, then shipping capacity is maximized, but worker ergonomics deteriorate requiring bending and stretching
Solution Approach 1:
The patent implements movable dunnage supports that can slide along tracks within the container, transforming fixed storage positions into dynamic, adjustable locations. This allows products to be positioned at ergonomically optimal heights and accessibility points while maintaining high storage capacity, directly resolving the contradiction between shipping capacity and worker ergonomics.
Solution Approach 2:
The container is divided into multiple segments with independent movable dunnage supports on tracks, allowing each section to be independently adjusted. This segmentation enables products of different sizes and weights to be optimally positioned without compromising overall shipping capacity, while providing ergonomic access points throughout the container.
2Ease of operation
If containers are designed for easy access from one position, then worker ergonomics improve, but container length must be reduced limiting storage capacity
Solution Approach 1:
The movable dunnage supports on tracks enable easy access to products at any position along the container length without requiring the worker to move to different locations. The supports can be slid to bring products forward to an ergonomic access point, maintaining full container length for maximum storage while providing consistent ergonomic access throughout.
Solution Approach 2:
The movable dunnage supports act as intermediaries between the fixed container structure and the worker. They facilitate easy access to products at any position by allowing the supports to be slid to ergonomic locations, eliminating the need to compromise container length while maintaining access efficiency.
3Loss of time
If heavy products are removed from rear positions, then access time is reduced, but worker strain increases due to distance and weight
Solution Approach 1:
The movable dunnage supports allow heavy products to be slid forward along the tracks to ergonomic access positions near the worker. This eliminates the need to reach into the rear of the container, reducing both access time and worker strain from handling heavy loads at difficult positions.
Solution Approach 2:
The movable dunnage supports enable products to be pre-positioned at ergonomic locations before the worker needs to access them. Heavy products can be slid forward to accessible positions in advance, reducing the physical effort and time required during the actual picking operation.
4Quantity of substance
If multiple containers are used to accommodate product size and weight, then shipping capacity per container is optimized, but shipping costs increase
Solution Approach 1:
The movable dunnage supports enable more efficient utilization of container space by allowing products of various sizes and weights to be optimally positioned. This maximizes the number of products that can be safely and ergonomically stored in a single container, reducing the total number of containers needed and lowering shipping costs.
Data Source
AI summary
A container comprising a metal frame or pallet box for holding product therein during shipment and being returned for reuse has a base and opposed sides, straight tracks, and a plurality of padded dunnage supports extending between the tracks. One type of padded dunnage support comprises end members and a tubular middle member, the end members being movable along the tracks. The padded dunnage supports support dunnage, such as pouches.