Sheet Metal Storage Container Structure for Leak-Proof Stacking
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Solution Overview
Problem
Existing storage containers used in storage and retrieval systems are flammable, emit toxic fumes, and suffer from leakage issues, particularly when storing food items, posing risks of fire spread and contamination.
Innovation Solution
The storage container is designed as a single unitary body with a base portion formed by a two-stage process involving stamping/drawing and turning a sheet metal blank to create a tray-shaped preform with a raised rim and flange, which is then connected to sidewalls and end walls, ensuring leak-proof integrity and structural rigidity, while using galvanized steel for enhanced ductility and optionally lined with food-grade materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If storage containers are made from conventional materials (plastic, wood, or thin metal), then they are easy to manufacture and lightweight, but they are flammable, emit toxic fumes, and lack structural rigidity for safe stacking
Solution Approach 1:
The storage container employs a composite construction combining galvanized steel sheets (0.5-1.5mm thickness) for structural strength and fire resistance, with food-grade plastic liners for leak-proof containment. This composite approach resolves the contradiction by integrating materials with complementary properties: the metal provides rigidity and fire safety while the plastic ensures ease of cleaning and food safety compliance.
Solution Approach 2:
The container is divided into distinct functional segments: a galvanized steel body for structural integrity and fire resistance, and a removable food-grade plastic liner for leak-proof containment and easy cleaning. This segmentation allows each component to be optimized for its specific function while maintaining overall manufacturing efficiency through modular assembly.
2Reliability
If storage containers are made from conventional materials, then manufacturing is simple and cost-effective, but they suffer from leakage issues and contamination risks when storing food items
Solution Approach 1:
The combination of galvanized steel outer shell with food-grade plastic liner creates a leak-proof barrier that prevents contamination. The plastic liner conforms to the steel container's interior, ensuring complete coverage and leak-proof integrity while maintaining ease of manufacture through standard molding processes for the liner and simple assembly operations.
Solution Approach 2:
The food-grade plastic liner acts as a flexible thin film that conforms to the rigid steel container interior, creating a leak-proof barrier. This flexible lining can be molded in standard manufacturing processes and easily installed, providing reliable leak-proof integrity without significantly increasing manufacturing complexity.
3Strength
If thicker metal sheets are used to increase structural rigidity, then stacking safety improves, but manufacturing cost and complexity increase
Solution Approach 1:
The composite structure of galvanized steel (0.5-1.5mm) with plastic liner provides optimal strength-to-cost ratio. The steel thickness is carefully selected to provide sufficient stacking strength while controlling manufacturing cost, and the plastic liner adds minimal weight and cost while significantly improving leak-proof performance and food safety compliance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a leak-proof and structurally rigid storage container capable of stacking safely, preventing fire and contamination, while maintaining efficient manufacturing processes and ensuring food safety.
Implementation Method 1
stamping or drawing a sheet metal blank into a drawing die to form a tray-shaped preform comprising a base with a raised rim and a flange
Implementation Method 2
turning the flange to define a connection surface that extends in the same direction as the raised rim of the tray-shaped preform
Data Source
AI summary
A method of manufacturing a storage container for storage in a stack in a grid framework structure comprising a plurality of storage columns, each of the plurality of storage columns being configured to store a stack of storage containers. The method comprises the steps of: forming a lower part of the storage container by the steps of: stamping or drawing a sheet metal blank into a drawing die to form a tray-shaped preform comprising a base with a raised rim and a flange; turning the flange to define a connection surface that extends in the same direction as the raised rim of the tray-shaped preform to form a container having a predefined depth; forming an upper part of the storage container by the step of: stamping sidewalls and/or end walls from one or more separate sheet metal blanks; attaching the lower part to the upper part by attaching the sidewalls and end walls to the connection surface of the container.