Produce Tray Reinforced Tabs for Stable, Space-Saving Stacking
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Solution Overview
Problem
Conventional tray-like containers with stacking tabs are inadequate for efficient stacking and space-saving in retail settings, lacking improved systems and methods for interlocking stacked containers.
Innovation Solution
A blank for forming a container with specific foldable side wall structures and stacking tab sections, including minor end flaps that overlap to form upright stacking tabs, and optional anti-nesting features to prevent containers from nesting, allowing for secure stacking and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional stacking tabs are used in tray-like containers, then containers can be stacked for transport and retail storage, but the stacking stability and space efficiency are inadequate
Solution Approach 1:
The stacking tab is divided into multiple separate tabs extending from different sides of the container, with each tab having a tab panel and a free end. This segmentation allows multiple containers to be stacked simultaneously with improved stability, as each tab can independently engage with the container below, distributing the stacking load across multiple points rather than relying on a single complex interlocking mechanism.
2Volume of moving object
If containers are designed for compact stacking, then space efficiency in retail settings is improved, but containers may unintentionally nest within each other
Solution Approach 1:
Anti-nesting features are incorporated into the container design, such as protrusions or barriers on the container walls that prevent the rim of another container from fully engaging. This preliminary anti-action stops the nesting behavior before it can occur, allowing containers to be stacked compactly side-by-side without the harmful effect of one container sliding inside another, thus maintaining space efficiency while eliminating the nesting problem.
3Strength
If stacking tabs are reinforced for better interlocking, then stacking stability improves, but the manufacturing complexity of the blank increases
Solution Approach 1:
The tab panels are foldably connected to the container walls using simple hinge lines that are integrated into the blank's existing structure. The tab panels themselves are formed from the same material and can be created using standard die-cutting and folding processes. This merging of the tab structure with the existing blank design allows for reinforced interlocking through multiple tabs without significantly increasing manufacturing complexity, as the tabs utilize the same material properties and formation techniques as the container body.
Data Source
AI summary
In accordance with at least one aspect of this disclosure, a blank for forming a container includes a base having a first pair of opposed base edges and a second pair of opposed base edges. The blank includes two first side wall structures, each first side wall structure foldably attached to one of the first base edges and two second side wall structures, each second side wall structure foldably attached to one of the second base edges.