Molded Plastic Tray with Grooved Rings for Stacked Containers
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Solution Overview
Problem
Existing cardboard packaging inserts lack structural stability, leading to instability during film wrapping, which necessitates interruptions in the wrapping process to reposition stacked containers.
Innovation Solution
The use of reinforced plastic inserts with grooved rings and protuberances provides structural support and maintains container positioning, accommodating various container shapes and preventing damage during stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If flat cardboard inserts are used to stack containers, then the packaging insert is simple and inexpensive, but the structural stability is insufficient leading to instability during film wrapping
Solution Approach 1:
The patent transitions from cardboard material to plastic material for the packaging insert. Plastic provides superior structural stability, strength, and rigidity compared to cardboard, enabling the insert to maintain its shape and support stacked containers during film wrapping without deforming or collapsing.
Solution Approach 2:
The plastic insert is divided into multiple functional segments: a base portion for support, vertical walls for containment, reinforcement ribs for structural strength, and protrusions for positioning. This segmentation allows each part to perform its specific function while collectively providing the required structural stability.
Solution Approach 3:
The patent introduces curved reinforcement ribs and arched structural elements within the plastic insert. These curved features provide structural reinforcement through geometric strength, distributing loads more effectively than flat surfaces and enhancing the overall rigidity of the insert without significantly increasing material usage.
2Reliability
If cardboard inserts are used, then the insert is inexpensive and simple to manufacture, but moisture sensitivity and mold formation occur
Solution Approach 1:
The patent replaces cardboard with plastic material for the packaging insert. Plastic provides superior structural stability, moisture resistance, and durability compared to cardboard, enabling the insert to maintain its shape and support stacked containers during film wrapping without deforming or collapsing.
3Strength
If plastic inserts with reinforcement are used, then structural stability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single molded plastic insert: the base provides support, vertical walls provide containment, reinforcement ribs provide structural strength, and protrusions provide positioning. This merging of functions into one component simplifies manufacturing compared to assembling multiple separate parts, despite the complexity of the molded geometry.
Data Source
AI summary
Film wrapped stacked containers having a molded transparent plastic tray 1 inserted between containers 6 and containers 5 are structurally stable to facilitate film wrapping. The top side of the tray has protuberances 2 forming groove rings 4 on the top side of the tray. The groove rings 4 acts to locate the bottom of the containers 5 on top of the tray in a preset configuration. The bottom of containers 5 rest within the groove rings. The bottom side of the tray has separation means such as cones 6 or other protuberances that act to separate and position the containers 6 beneath the tray 1. By providing a plastic insert that can be molded to a preset configuration, structural stability can be provided for containers with different shapes.