Reusable Knock-Down Shipping Container With Porous Mesh
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Solution Overview
Problem
Conventional shipping containers, particularly those made of plastic and cardboard, face issues with sanitization, recycling, and reusability due to the use of disposable fasteners and structural limitations that hinder efficient handling and storage.
Innovation Solution
A collapsible and reusable shipping container formed from a single piece of flexible, woven polypropylene mesh material with integrated longitudinal creases and a semi-rigid ABS or urethane bottom, allowing for easy assembly and disassembly without the need for tape, staples, or other disposable fasteners, and featuring a hinged flap and zipper for secure closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If plastic containers are used for shipping, then durability and reusability are improved, but sanitization cost and time increase
Solution Approach 1:
The container body is made from porous polypropylene nonwoven material that allows fluids to penetrate through it. This porosity enables efficient sanitization where sanitizing fluids can flow through the container walls, dramatically reducing sanitization time and cost while maintaining the container's durability and reusability.
2Ease of manufacture
If cardboard boxes are used for shipping, then cost is reduced, but reusability and structural integrity deteriorate
Solution Approach 1:
The container combines polypropylene nonwoven fabric for the flexible body with rigid ABS plastic corners and a rigid polypropylene lid. This composite construction provides the structural integrity and reusability of plastic containers while maintaining cost-effectiveness, and the porous nature of the nonwoven material enables efficient sanitization for repeated use.
3Reliability
If flaps are added to box tops for closure, then sealing capability is improved, but user access and ease of operation worsen
Solution Approach 1:
The lid is designed to be removable rather than fixed with flaps. This dynamic design allows the lid to be completely removed for easy access to the container interior, then replaced to provide sealing when needed. The removable lid eliminates the compromise of fixed flaps that partially obstruct access while attempting to provide sealing.
4Strength
If tape and staples are used to assemble boxes, then structural strength is improved, but recyclability and reusability worsen
Solution Approach 1:
The container is constructed from a single piece of polypropylene nonwoven material that is folded and heat-sealed at the seams, eliminating the need for tape, staples, or other external fasteners. This segmented folding design provides structural strength through the rigid ABS corners and heat-sealed seams while maintaining full recyclability and reusability without disposable fastening materials.
Data Source
AI summary
A shipping container formed from a single piece of flexible planar material as a continuous and contiguous structure foldable into a reusable, knock-down box. The shell body comprises a fabric or mesh and includes a semi-rigid bottom panel and a zipper disposed within an end panel securing an end panel flap. A pair of opposing handles are formed in the end portion and a resealable label pouch is affixed to a top panel.