Nestable Wheelbarrow Carton with Hopper Extension

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Solution Overview

Problem

Existing carton systems for wheelbarrow kits are inefficient in minimizing material usage and cost, as they often enclose significant empty space and are not stackable, leading to increased shipping and storage challenges.

Innovation Solution

A nestable carton system with generally rectangular, planar sides that encloses the rim portion of the hopper and features a first opening for the bucket portion to extend out, allowing multiple cartons to be stacked with the hopper of a lower carton extending through the opening of the adjacent carton, reducing empty space and enabling efficient stacking and shipping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a carton is designed to enclose the hopper in its traditional wedge-like shape, then the hopper is protected during shipping, but the carton encloses a significant volume of empty space and is not stackable

Engineering Contradiction:

Improveprotection of hopperVSAvoidempty space in carton

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The patent applies nesting by allowing the hopper to extend through the carton and nest within the hopper of the carton above it. The bucket portion of the lower hopper extends through the bottom opening of the upper carton and nests inside the upper hopper, eliminating empty space and enabling vertical stacking of cartons.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent transitions from enclosing the entire hopper within the carton to a configuration where the hopper extends through the carton in the vertical dimension. This dimensional change allows the hopper to protrude through the bottom opening and nest with the carton below, transforming the packaging from a closed enclosure to an open nested structure.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If the hopper is completely enclosed in the carton, then the hopper is protected, but the carton cannot be efficiently stacked with other cartons

Engineering Contradiction:

Improveprotection of hopperVSAvoidstacking efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent enables stacking efficiency by having cartons nest vertically. The hopper extends through the bottom opening of each carton and nests within the hopper of the carton above, creating a stable stacked configuration where multiple cartons can be efficiently stored and transported.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The carton is segmented with separate top and bottom openings, allowing the hopper to pass through while maintaining protective enclosure. This segmentation enables the hopper to extend outward for nesting while the carton body still provides protection during shipping and stacking.

Inventive Principle:

Principle #1Segmentation

3Volume of stationary object

If sectional handle members are used to reduce carton size, then the carton can be smaller, but the handles are weaker and require additional assembly steps

Engineering Contradiction:

Improvecarton sizeVSAvoidstrength of handle members

Core Design Contradiction:

Volume of stationary objectVSStrength

Solution Approach 1:

Instead of sectioning the handles to reduce carton size, the patent inverts the approach by having the handles extend through the carton as continuous unitary members. The handles protrude through the top opening and are protected during shipping without requiring segmentation, maintaining strength while enabling compact stacking configurations.

Inventive Principle:

Principle #13The other way round (Inversion)

4Reliability

If the carton encloses the entire hopper, then the hopper is protected, but expensive carton material is used to enclose empty space

Engineering Contradiction:

Improveprotection of hopperVSAvoidcarton material usage

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent extracts the hopper from complete enclosure within the carton, allowing it to extend through the bottom opening. This extraction eliminates the need for the carton to enclose the entire hopper volume, reducing carton material usage while maintaining protection during shipping through the nested configuration.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The nested configuration allows the hopper to extend through the carton and nest within the hopper of the carton above, eliminating empty space that would otherwise require carton enclosure. This nesting arrangement reduces material usage by allowing cartons to be stacked vertically rather than requiring horizontal spacing.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS9701462B2Nestable carton for wheelbarrow kit

Publication Date: 2017.07.11 THE IAMS CO

AI summary

A carton for a wheelbarrow kit having a hopper with rim portion and a tapered bucket portion, the carton structured to enclose the rim portion of the hopper and having a first opening allowing the bucket portion of the hopper to extend out of the carton. The carton further provides a second opening generally aligned with the first opening, but disposed on the side of the carton opposed to the first opening. The hopper is inverted in the carton so that the rim is disposed at the bottom of the carton and the hopper extends upwardly. In this configuration, multiple cartons enclosing wheelbarrow kits may be stacked on top of each other with the hopper of a lower carton extending upwardly through the second opening of the adjacent carton and into the partially enclosed space of the hopper in the carton above.