Nestable Rigid U-Crates With Slit Base Walls
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Rigid U-shaped packaging containers face high shipping and storage costs due to empty space when shipped in assembled form, and existing solutions that allow for stacking compromise the structural integrity and strength of the containers.
Innovation Solution
The design features preformed, rigid U-shaped members with slits in the base wall that allow them to nest into a W-configuration for increased density, maintaining structural integrity and strength through narrow slits and optional reinforcement and coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If U-shaped members are shipped and stored in assembled form, then structural integrity is maintained, but shipping and storage costs increase due to empty space
Solution Approach 1:
The base wall is divided into multiple segments by forming slits through its thickness, allowing the U-shaped member to be segmented into collapsible sections that can nest within each other, reducing shipping volume while maintaining structural integrity when assembled
Solution Approach 2:
The U-shaped members are designed to nest within one another when collapsed, similar to nested dolls, allowing multiple containers to be stacked compactly for shipping and storage, significantly reducing the volume occupied by empty space
2Ease of operation
If embossing or cutting is applied to enable stacking, then nesting capability is improved, but structural integrity deteriorates
Solution Approach 1:
The slits are positioned specifically in the base wall rather than throughout the entire U-shaped member, concentrating the flexibility needed for nesting in the base while leaving the side walls and upper portions intact to maintain structural integrity and protection capabilities
Solution Approach 2:
The slits change the physical parameter of the base wall from rigid to flexible, enabling the base to open and collapse for nesting, while the overall U-shaped member maintains its structural parameters through the strategic placement and dimensions of the slits
Data Source
AI summary
A high density nesting packaging container has first and second preformed, rigid U-shaped members each having a U-shaped cross-section. The U-shaped members are configured to fit into one another to form a rectangular cross-section container. Each of the U-shaped members has a base wall and opposing side walls, the intersection of the base and side walls being rigid. The base wall has a thickness. A narrow slit is formed in the base wall, extending longitudinally along the base wall and formed from an inner surface of the wall into the thickness of the base wall. The base wall is foldable along the slit so as to form a generally W-configuration cross-section. The thus W-configuration, U-shaped members are nestable with each other. When the U-shaped member is unfolded to the U-shaped cross-section, the opposing surfaces formed by the slit abut one another to maintain the crate in the U-shaped cross-section.