Shipping Container Cushion-Tab Structure for Material Waste Reduction
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Solution Overview
Problem
Existing shipping containers are inefficient in space utilization and costly due to the need for excessive materials like air-filled plastic pouches and shredded paper, leading to waste and high expenses.
Innovation Solution
A shipping container system comprising an outer container with a product compartment base and lid, featuring retention and support tabs, and an inner compartment with suspension elements, designed to securely hold products while minimizing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional filling materials like air-filled plastic pouches or shredded paper are used to fill shipping container space, then products can be protected during shipping, but material cost increases and excessive waste is generated
Solution Approach 1:
The packaging structure merges the protective function with the container structure itself by integrating retention tabs and support elements directly into the container walls and lid, eliminating the need for separate filling materials while maintaining product protection
Solution Approach 2:
The container structure provides its own protective function through integrated retention tabs and support elements that secure products without requiring external filling materials, making the system self-sufficient
2Stability of the object's composition
If traditional filling materials are used to secure products in shipping containers, then products remain positioned during shipping, but material cost increases
Solution Approach 1:
The retention tabs and support elements are integrated directly into the container structure, combining the positioning function with the container itself and eliminating the need for separate positioning materials
Solution Approach 2:
The container structure secures products through its own integrated retention mechanisms rather than relying on external filling materials, achieving self-service functionality
3Volume of stationary object
If excessive filling materials are used to maximize space utilization, then container volume is fully utilized, but material cost and waste increase
Solution Approach 1:
The container is segmented into functional zones with retention tabs and support elements positioned to efficiently utilize space without requiring excessive filling materials, creating optimized compartments for product placement
Solution Approach 2:
The design changes the structural parameters of the container by adding integrated retention features that improve space utilization efficiency without proportionally increasing material usage
Data Source
AI summary
There is disclosed a shipping container system comprising an outer container and a product compartment inside the outer container, wherein the product compartment comprises a product compartment base and a product compartment lid, wherein the product compartment base comprises a plurality of retention tabs maintaining a cushion gap between the product compartment and sidewalls of the outer container, a plurality of support tabs maintaining a cushion gap between the product compartment and a base of the outer container, and a pair of suspension units maintaining a cushion gap between the product compartment and each end of a pair of opposing ends of the outer container, and wherein the product compartment lid includes a plurality of space tabs maintaining a cushion gap between the product compartment and a lid of the outer container, wherein the cushion gaps are maintained between the product compartment and the outer container when the outer container is in a closed configuration.