Nesting Container Carrier With Ledge Stacking
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Solution Overview
Problem
Existing container carriers are limited in their ability to securely transport heavier products and those with caps, as they are often flat and require three-dimensional support, leading to inefficient packaging and increased shipping costs due to larger size and reduced capacity per shipping box.
Innovation Solution
A container carrier with an integrally molded body featuring a plurality of annular structures connected by bridges, each with side wall portions and voids, flanges, and a graspable loop, allowing for secure stacking and efficient nesting to maximize shipping capacity, while accommodating different container sizes and types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If container carriers are made flat as in prior art, then shipping efficiency is improved, but the ability to securely transport heavier products and bottles with caps deteriorates
Solution Approach 1:
The patent transitions from flat two-dimensional container carriers to three-dimensional carriers with vertical walls extending upward from the base. This dimensional change allows the carriers to provide adequate support for heavier products and bottles with caps while still maintaining nesting capability for efficient shipping. The vertical dimension adds structural support without significantly increasing the horizontal footprint.
2Reliability
If container carriers are made with three-dimensional support structures, then the ability to support heavier products is improved, but shipping efficiency deteriorates due to increased size
Solution Approach 1:
The patent designs the container carrier with nesting features including recesses in the top surface and protrusions on the bottom surface that allow carriers to nest within each other when stacked. This nesting capability enables three-dimensional carriers with adequate support structures to be compacted for efficient shipping, maximizing the number of carriers per shipping box while maintaining the structural integrity needed for supporting heavier products.
3Adaptability or versatility
If container carriers are made taller to accommodate bottle caps, then accommodation capability is improved, but nesting efficiency deteriorates
Solution Approach 1:
The patent applies different wall heights at different locations within the carrier. The side walls extend to a first height to accommodate bottle caps, while the partition walls between compartments extend to a second height that is less than the first height. This localized variation in wall height provides the necessary accommodation for bottle caps while maintaining optimal nesting efficiency by reducing the overall height of the carrier structure.
Data Source
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AI summary
A container carrier (10) and manufacturing method therefore are provided. The container carrier (10) may include a plurality of annular structures (12) connected by bridges (14). The annular structures (12) may include a side wall (16) formed of side wall portions (18) separated by side wall voids (20). Each side wall portion (18) has an upper and a lower side wall segment (24, 26) joined at a ledge (28), with the upper side wall segment (24) having a smaller diameter (D1) relative to the lower side wall segment (26) of the side wall portion (18). Flanges (30) are positioned at the bottom of each side wall void (20) to collectively engage containers (CON). The bottom portion (32) of the lower side wall segment (26) has an inner diameter (ID) that is larger than the outer diameter (OD) of the upper side wall (24) and smaller than the outer diameter (LOD) of the ledge (28) such that the bottom (32) of a first container carrier (10) will rest upon the ledge (28) of a second, same-shaped container carrier (10) when stacked.