Nested Sleeve Container Assembly for Automated Retail Display
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Solution Overview
Problem
Existing two-piece display-ready containers for shipping and displaying goods are not cost-effective and efficient in their design, particularly in warehouse and supermarket settings, as they require manual handling and lack a simple, automated assembly process.
Innovation Solution
A container design comprising an inner and outer sleeve formed from score-cut blanks that can be easily assembled and disassembled, featuring tear-away sections and foldable panels for secure stacking and easy display access, allowing for efficient shipping and display without the need for complex assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional two-piece containers are used for shipping and displaying goods, then the containers can be stacked and displayed, but they require manual handling and lack automated assembly capability
Solution Approach 1:
The container is divided into two separate sections: an outer container for shipping and an inner container for display. The outer container includes a body and a separate lid that can be easily detached. This segmentation allows the outer container to be automatically handled during shipping while the inner container can be easily opened manually for display purposes, thus resolving the contradiction between automated assembly capability and ease of manual operation.
Solution Approach 2:
The inner container is designed to nest within the outer container. The inner container fits inside the outer container's body, allowing for compact stacking during shipping. When ready for display, the inner container can be easily removed from the outer container. This nesting design enables automated handling of the nested structure while maintaining simple manual access to the inner container for display operations.
2Productivity
If complex assembly steps are used for container assembly, then secure stacking and display are achieved, but cost-effectiveness and efficiency are reduced
Solution Approach 1:
The outer container is pre-assembled with integrated stacking features and the lid is pre-formed with attachment structures. The inner container is pre-formed with complementary features that align with the outer container. This preliminary preparation of assembly features allows for rapid, tool-free assembly by simply nesting the inner container into the outer container and attaching the lid, thereby improving productivity while maintaining ease of manufacture.
Solution Approach 2:
The container design incorporates self-aligning features where the inner container automatically positions itself within the outer container during insertion. The stacking features and attachment mechanisms are designed to engage automatically without requiring manual alignment or complex assembly steps. This self-service capability significantly improves assembly efficiency while keeping the manufacturing process simple and cost-effective.
3Ease of operation
If display panels are folded down or removed for display access, then product visibility is improved, but structural integrity and stacking stability are compromised
Solution Approach 1:
The container is segmented into a stable outer container structure and a separate inner container that houses the display panel. The outer container maintains its structural integrity and stacking stability throughout the process. The inner container with the display panel can be independently opened or removed for display access without affecting the outer container's stability, thus resolving the contradiction between display access and stacking stability.
Solution Approach 2:
The inner container with the display panel is nested within the outer container. When display access is needed, the inner container can be easily removed from the outer container, allowing the display panel to be opened or accessed without compromising the outer container's structural integrity or stacking stability. The outer container remains stable and stackable even when the inner container is removed or opened.
Data Source
AI summary
A container preassembly which has an inner sleeve in a flat unopened position disposed within an outer sleeve in a flat unopened position. The two sleeves are adapted to form the two ends of the container and are secured together in the aligned relationship of the final open container, thereby allowing the preassembly to be opened into the form of the final container without requiring further adjustment. Once opened, the flaps for forming the container bottom are folded to create a container ready for use. A method of making the container preassembly is also provided.