Reusable Corrugated Plastic Shipping Container
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Solution Overview
Problem
Conventional paper boxes used for shipping bananas and tropical fruit are expensive, labor-intensive to assemble and disassemble, and lack structural rigidity, leading to increased shipment costs and susceptibility to physical damage.
Innovation Solution
A reusable, corrugated plastic container with a four-sided sleeve and opposing trays, featuring alignment tabs and a continuous outer wall for easy assembly and secure interconnection, allowing for efficient packaging, display, and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional paper boxes are used for shipping bananas and tropical fruit, then the product can be transported with basic protection, but the containers are expensive, single-use, and significantly increase overall shipment costs
Solution Approach 1:
The patent implements a reusable container system where the rigid plastic container and corrugated cardboard insert are designed to be returned to the supplier after delivery. The container is discarded only when damaged beyond repair, while the insert can be collapsed and reused multiple times. This recovery and reuse system eliminates the need for single-use containers, significantly reducing shipment costs while maintaining reliable product protection throughout multiple transport cycles.
Solution Approach 2:
The patent employs a composite container structure combining rigid plastic for the outer shell with corrugated cardboard for the internal insert. This composite design leverages the strength and durability of plastic for protection while using the compressible, lightweight cardboard for structural support and cost-effectiveness. The combination provides reliable product protection at lower cost compared to solid plastic containers.
2Reliability
If conventional paper boxes are used, then basic packaging is provided, but the packing and unpacking process is relatively laborious and time-consuming
Solution Approach 1:
The patent divides the container into two separate components: a rigid plastic outer container and a removable corrugated cardboard insert. The insert is designed to be easily inserted into and removed from the plastic container without tools or complex assembly steps. This segmentation allows the insert to be quickly swapped during packing and unpacking operations, significantly reducing labor time while maintaining reliable packaging function.
Solution Approach 2:
The corrugated cardboard insert is designed with collapsible sides that can be compressed flat for efficient storage and transport when empty. During packing, the insert expands to its full shape to provide structural support. This dynamic transformation capability allows the packaging to adapt between storage and use states, reducing handling time and effort during packing and unpacking operations.
3Reliability
If conventional paper boxes are used, then basic containment is achieved, but the structural rigidity is limited and the product is susceptible to physical damage
Solution Approach 1:
The patent uses a composite structure combining rigid plastic for the outer container with corrugated cardboard for the inner insert. The rigid plastic provides superior structural strength and resistance to physical damage compared to conventional paper boxes, while the corrugated cardboard adds internal support and cushioning. This composite approach significantly enhances product protection and container rigidity.
Solution Approach 2:
The corrugated cardboard insert is positioned inside the rigid plastic container to provide beforehand cushioning and structural support for the product. The insert's corrugated structure absorbs shocks and prevents direct contact between the product and hard container walls, reducing susceptibility to physical damage before damage can occur during transport.
4Strength
If a reusable rigid container is used, then structural strength and reusability are improved, but the assembly process becomes more complex requiring precise fitting of components
Solution Approach 1:
The patent applies local quality by designing the corrugated cardboard insert with specific structural characteristics at critical locations. The insert features reinforced corners, tapered edges, and strategically positioned flutes that guide it into precise alignment with the rigid plastic container during assembly. These localized structural enhancements simplify the assembly process by providing natural alignment cues, reducing overall assembly complexity despite the container's high rigidity requirements.
Data Source
AI summary
A container for the shipment and display of a product includes a corrugated plastic sleeve that is selectively enclosed by a pair of opposing plastic trays. The sleeve includes four adjacent panels that together define open top and bottom ends. Alignment tabs are formed on the top and bottom ends of the sleeve and fittingly protrude into complementary slots in each tray to help retain container in an assembled condition. Each tray includes a rectangular plate and an outer continuous wall which protrudes from the peripheral edge of the plate at an obtuse angle, which enables multiple trays to be arranged as a nested stack. A plurality of thru-holes is provided in the sleeve for ventilation and is arranged so that select thru-holes in adjacent panels axially align when the sleeve is collapsed into a flattened condition, thereby facilitating the stacking of used sleeves onto posts for subsequent cleaning.