Produce Tray Orientation and Nesting Design
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Solution Overview
Problem
Conventional produce trays are inefficient in maximizing storage capacity and handling flexibility, particularly in varying orientations, and lack effective methods for protecting produce during movement and storage.
Innovation Solution
The design of produce trays with adjustable orientation capabilities, featuring a unique configuration of bases, inner and outer sidewalls, posts, and a handle that allows for horizontal or vertical stacking, along with a method of manufacturing using thermoformed polymeric materials and a sealing film to secure produce, enhancing storage density and shock absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional produce trays are used, then storage capacity is limited, but handling flexibility and protection are also insufficient
Solution Approach 1:
The produce tray is designed with a foldable handle that can transition between extended and retracted positions, allowing the tray to adapt to different handling requirements. When extended, it provides easy carrying; when retracted, it enables compact nesting for efficient storage and transportation.
Solution Approach 2:
The trays are designed to nest within each other when the handle is retracted, maximizing storage density during transportation and storage. Multiple trays can be stacked vertically or horizontally, optimizing the use of available space while maintaining accessibility when needed.
2Ease of manufacture
If produce trays are designed for single orientation, then manufacturing is simple, but storage efficiency in varying orientations is reduced
Solution Approach 1:
The tray design incorporates asymmetric features such as the positioned handle and base configuration that enable stable stacking in multiple orientations. The asymmetric design allows trays to be stacked vertically or horizontally while maintaining structural integrity and stability, doubling the effective storage capacity without complicating the manufacturing process.
3Device complexity
If produce trays lack protection mechanisms, then device complexity is low, but produce damage during movement increases
Solution Approach 1:
The tray design incorporates shock-absorbing features in the base and wall structures that provide protection against damage during handling and transportation. The molded construction includes integrated cushioning elements that absorb impacts before they reach the produce, reducing damage without requiring additional protective components.
4Ease of manufacture
If produce trays are not recyclable, then manufacturing cost is low, but environmental impact increases
Solution Approach 1:
The tray is manufactured from polymeric material that can be designed with varying degrees of recyclability. By selecting appropriate polymer types and manufacturing processes, the tray achieves both cost-effectiveness and recyclability, allowing it to be reused multiple times or recycled at the end of its service life, reducing environmental impact while maintaining manufacturing efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The trays enable efficient storage of a higher number of produce items in both horizontal and vertical orientations, providing better protection against damage during movement and storage, while being fully recyclable and easy to use.
Implementation Method 1
a method of manufacturing using thermoformed polymeric materials and a sealing film to secure produce, enhancing storage density and shock absorption
Data Source
AI summary
A produce tray assembly includes a plurality of produce trays and a box. Each produce tray includes a plurality of bases, a plurality of inner and outer sidewalls, a lip, and a handle. The sidewalls extending from the bases. The sidewalls define cavities sized and configured to receive produce. The lip extends from the outer sidewalls. The lip includes a planar surface. The box is configured to hold a first amount of produce trays in response to the of produce trays being oriented in a horizontal position where the planar surface extends horizontally. The box is configured to hold a second amount of produce trays in response to the produce trays being oriented in a vertical position where the planar surface extends vertically. The second amount of the produce trays is greater than the first amount of produce trays.