Sleeve Pack Assembly With Segmented Dividers
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Solution Overview
Problem
Current sleeve pack assembly methods for returnable bulk containers are inefficient and costly due to the need for multiple handling steps and reverse order unloading, which can be unsafe and inefficient in distribution chains, especially when dealing with multiple small orders.
Innovation Solution
A sleeve pack assembly comprising a pallet, dividers, and top cap with interlocking sleeves and latching mechanisms, allowing for customizable configurations and secure stacking, which can be customized for specific facilities and optimized for efficient transportation and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple small orders are palletized on a single pallet using traditional methods, then all items must be delivered in reverse order of picking (Last In, First Out), but this increases handling complexity and unloading time
Solution Approach 1:
The pallet is divided into multiple compartments using dividers, allowing different orders to be separated into distinct sections. This segmentation enables independent access to each compartment without requiring complete unstacking or reverse-order handling, thus improving unloading efficiency while maintaining manageable complexity through modular organization
Solution Approach 2:
The invention transitions from single-layer palletization to multi-level stacking with dividers creating vertical and horizontal compartments. This dimensional organization allows simultaneous access to multiple orders at different heights and positions, eliminating the reverse-order constraint and reducing handling complexity
2Productivity
If multiple pallets are stacked for transportation to maximize truck loads, then shipping efficiency is improved, but unloading and breaking down becomes more time-consuming and costly
Solution Approach 1:
Each pallet is segmented into ordered compartments that can be independently accessed. When pallets are stacked for transportation, the divider system allows selective removal of specific compartments without requiring complete unstacking, thus maintaining shipping efficiency while significantly reducing unloading time
Solution Approach 2:
Orders are pre-organized into separate compartments during palletization before stacking. This preliminary segmentation allows receiving facilities to directly access and remove specific orders from stacked pallets without time-consuming breakdown procedures, reducing unloading time while maintaining efficient space utilization
3Stability of the object's composition
If traditional sleeve pack assembly uses passive interference fit or active latching mechanisms, then structural stability is achieved, but assembly and disassembly processes remain complex and time-consuming
Solution Approach 1:
The sleeve pack assembly is segmented into modular components (sleeves, dividers, caps) with standardized connection interfaces. This segmentation allows simple snap-fit or latched connections that provide structural stability while enabling rapid assembly and disassembly without complex procedures
Solution Approach 2:
The divider system incorporates self-latching mechanisms that automatically secure compartments when assembled, providing structural stability without requiring complex manual operations. The design allows workers to simply position components and the latching system engages automatically, reducing assembly complexity and time
Data Source
AI summary
A sleeve pack (10) is disclosed having a pallet (50) and top cap (80) with one or more dividers (60) disposed therebetween and one or more sleeves (70) disposed between the pallet (50) and each divider (60) or top cap (80).