Nestable Rigid U-Crates With Base Wall Slits
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Solution Overview
Problem
U-shaped packaging members require assembly for shipping and storage, leading to high costs due to empty space and potential structural integrity issues when embossed or cut for nesting.
Innovation Solution
Preformed, rigid U-shaped members with longitudinal slits in the base wall that allow them to nest and form a W-configuration for increased density, maintaining structural integrity and strength.
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 patent implements nesting by forming slits in the base wall of U-shaped members, allowing them to be collapsed into a W-configuration for compact stacking. Inner U-shaped members fit within outer members during shipping and storage, dramatically reducing the volume occupied while maintaining structural integrity when assembled for use
2Volume of stationary object
If U-shaped members are embossed or cut to enable nesting, then storage density improves, but structural integrity deteriorates
Solution Approach 1:
The patent applies segmentation by forming slits in the base wall that divide it into sections that can flex relative to each other. This allows the base to collapse into a W-configuration for nesting while the segmented structure maintains sufficient strength. The slits create controlled flexibility points that enable compression without compromising the overall structural integrity of the U-shaped member
3Adaptability or versatility
If base wall is opened along slit to form W-configuration, then nestability improves, but strength may be reduced
Solution Approach 1:
The patent implements dynamics by creating a base wall that can transition between two states: the closed U-configuration for strength and protection during use, and the open W-configuration for nesting during storage. The slits provide controlled flexibility that allows dynamic transformation between these states while maintaining adequate strength in both configurations
Data Source
AI summary
A high density nesting packaging element is a preformed, rigid U-shaped member. The U-shaped member has a base wall and upstanding opposing side walls, in which the intersection of the base and side walls is rigid. The base wall has a thickness and a narrow slit is formed in the base wall, extending longitudinally along the base wall. The slit is 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-shaped configuration cross-section. When folded into the W-shaped configuration, the members are nestable with each other. When the member is unfolded to the U-shaped cross-section, the opposing surfaces formed by the slit abut one another to maintain the member in the U-shaped configuration.