Collapsible Returnable Rack With Swappable Dunnage for Reuse
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Solution Overview
Problem
Existing returnable shipping containers are often customized and discarded after use, leading to inefficiencies and material waste, as they are not designed for reuse and do not optimize shipping densities or asset utilization.
Innovation Solution
A modular, customizable returnable rack system that allows racks to be selectively collapsed and stacked, with removable dunnage structures that can be configured for different products, enabling efficient reuse and maximizing space in shipping containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If racks are customized for specific applications, then they can be optimized for particular products, but they become wasteful and inefficient when discarded after use
Solution Approach 1:
The rack system is divided into two main segments: a permanent base structure (frame with posts) and removable dunnage structures. The base is designed to be reused across multiple applications, while the dunnage is customized for specific products and can be easily removed and replaced. This segmentation allows the expensive structural components to be retained and reused, minimizing material waste.
Solution Approach 2:
The rack base is designed as a universal platform that can accommodate multiple types of products through interchangeable dunnage configurations. The standard footprint and modular design allow the same base to serve different applications by simply changing the dunnage, making the rack system multi-functional rather than single-purpose.
2Duration of action of stationary object
If racks are designed with sturdy, durable materials to withstand stacking loads, then they can be reused, but the cost of producing new dunnage systems for different products remains high
Solution Approach 1:
The system separates the high-cost, long-life structural components (base and posts) from the application-specific dunnage components. This allows investment in durable materials for the base that can be reused indefinitely, while dunnage can be manufactured more economically and swapped out as needed for different product configurations.
Solution Approach 2:
The design allows for the discarding or replacement of only the dunnage portion when changing applications, while recovering and reusing the expensive base structure. This selective replacement strategy minimizes overall material costs while maintaining the ability to adapt to different products.
3Loss of energy
If racks are designed with modular standard footprints for efficient shipping, then shipping costs are reduced, but the racks must still be customized for each application
Solution Approach 1:
The rack base is designed with a universal standard footprint that optimizes shipping efficiency and space utilization. This same universal base then accommodates application-specific customization through interchangeable dunnage, allowing the system to maintain both shipping efficiency and product adaptability without compromise.
Solution Approach 2:
The rack system transitions from a static, fixed configuration to a dynamic, reconfigurable system. The base remains static with standardized dimensions for efficient shipping, while the dunnage components can be dynamically added, removed, or reconfigured to adapt to different product requirements, providing flexibility without sacrificing shipping optimization.
Data Source
AI summary
A customizable returnable rack system for shipping products is provided. The system includes a plurality of racks (10), wherein each rack (10) is selectively displaceable between a collapsed position and an upright position. The racks (10) are adapted to be stacked upon one another in either the collapsed or upright position. The system further includes a first removable dunnage structure (22) couplable to a rack (10) and configured to receive a first type of product and a second removable dunnage structure (22) couplable to a rack (10) and configured to receive a second type of product.