Stackable Corrugated Box Air Circulation Design
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Solution Overview
Problem
The flash freezing process for frozen food products is inefficient due to slow freezing of inner pallet areas, requiring manual restacking with spacers to enhance air flow, which is time-consuming and labor-intensive for large volumes.
Innovation Solution
A stackable corrugated wax box with a five-sided structure and specific post configurations (corner, edge, and center posts) to improve air circulation around products, facilitating faster freezing without the need for manual restacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If manual restacking with spacers is used to enhance air flow, then freezing speed of inner pallet areas is improved, but labor time and handling complexity increase significantly
Solution Approach 1:
The box design incorporates built-in air circulation features (side walls with openings, internal structure) that pre-establish the necessary air flow paths before freezing begins. This preliminary design eliminates the need for manual restacking with spacers, as the box itself is prepared to facilitate optimal air circulation from the start of the freezing process.
Solution Approach 2:
The box structure is designed to automatically facilitate air circulation and freezing without requiring external intervention or manual restacking. The internal geometry and wall configurations self-regulate to maintain proper air flow patterns, making the system self-sufficient for achieving uniform freezing throughout the pallet.
2Productivity
If manual restacking with spacers is performed to improve air circulation, then freezing efficiency is improved, but labor intensity and operational complexity increase
Solution Approach 1:
The air circulation capabilities are built into the box design itself through pre-configured wall openings and internal structures. This preliminary design ensures that optimal air flow is established before the freezing process begins, eliminating the need for complex manual restacking operations with spacers to achieve similar results.
3Ease of manufacture
If traditional cardboard boxes are used without special structure, then manufacturing simplicity is maintained, but air circulation and freezing speed are insufficient
Solution Approach 1:
Rather than fundamentally redesigning the entire box structure, the invention applies localized modifications to specific areas (side walls with openings, internal geometry adjustments) that specifically target air circulation pathways. These focused local changes maintain the overall simplicity of box manufacturing while dramatically improving freezing performance through enhanced air flow in critical areas.
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
Enhances air circulation for rapid freezing of frozen food products, reducing handling time and manpower by allowing for efficient stacking and freezing of bulk products on pallets.
Implementation Method 1
The corner posts, the edge posts, and the center posts may be configured to facilitate flash freezing of the products in the cavity of the stacking device by improving circulation of air about each of a plurality of the stacking devices stacked on the pallet.
Data Source
AI summary
A stackable corrugated was box is a specialized box to be used to store food products in cold storage. The box is supplied with a built in “slat” or spacer at the bottom of the box. The spacer is generally rectangular shaped and is approximately thirteen by nineteen inches (13×19″) and one inch (1″) thick. The bottom surface is provided with approximately eight (8) pedestals to produce an “egg-crate” like bottom with open areas all of the way across the bottom. This open area allows for air flow across the entire bottom area of the box, thus allowing for rapid freezing times when compared to conventional boxes that are stacked upon one another.