Rigid Tray Container Indexing Tabs for Batch Sorting
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Solution Overview
Problem
Current sorting systems face inefficiencies and production control challenges due to the varied sizes and materials of containers used, leading to complex handling procedures and reduced productivity.
Innovation Solution
A stackable, open-ended rigid tray container with indexing tabs and cavities for alignment, along with stabilizing indentations and a secure lid system, is introduced for batch processing, enabling standardized sorting and improved production control through a method involving tray identification and orientation adjustment for efficient loading into mass containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If various sizes and shapes of containers are used, then different loading tolerances and material strengths are accommodated, but handling procedures become complicated
Solution Approach 1:
The patent applies homogeneity by standardizing all containers to a uniform tray design with consistent dimensions, materials, and structural features. This eliminates the variety of container types while maintaining the ability to handle different loads through the standardized design's inherent flexibility and reinforcement features.
2Productivity
If individual sorting is performed, then effective sorting is achieved, but production control becomes difficult and inefficiencies arise
Solution Approach 1:
The patent merges multiple individual sorting operations into a single batch processing operation. Multiple items are sorted together in one tray simultaneously, combining what would otherwise be separate sequential operations into one unified process, thereby improving productivity while simplifying control.
Solution Approach 2:
The patent applies preliminary action by performing batch sorting in advance before final destination assignment. Items are pre-sorted into categories within the tray, and then the entire tray is routed as a unit, allowing production control to operate at a higher level rather than tracking each individual item.
3Ease of operation
If standardized trays with indexing features are used, then alignment and stacking are improved, but device complexity increases
Solution Approach 1:
The patent uses asymmetry in the indexing tab and cavity design to ensure proper orientation during stacking. The tab on one tray fits into the cavity of the tray below in a specific orientation, preventing incorrect stacking while maintaining simplicity through the straightforward geometric shapes used.
Data Source
AI summary
Embodiments of this disclosure include a rigid tray container and methods and equipment for using the rigid tray container in batched process operations. In one embodiment, a mass container is sized and dimensioned to receive one or several rigid tray containers. In other embodiments, equipment is configured to lid/unlid, secure, stack, load/unload, and buffer rigid tray containers. In other embodiments, equipment is configured to stack and stage mass containers. In some embodiments, methods are provided for batch processing items.