Stackable container, a stackable container package, and a method of use of the same
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Solution Overview
Problem
Existing stackable containers face challenges in achieving a balance between reduced material weight and maintaining structural rigidity to carry a pre-determined top load, while also being efficient for shipping and stacking.
Innovation Solution
The container design features a side wall thickness profile with varying thicknesses to minimize material usage while ensuring structural integrity, including a tapered side wall and angled shoulder for efficient stacking and a lightweight yet robust construction, allowing for a high top load rating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If material is reduced to decrease container weight, then weight is reduced, but structural rigidity deteriorates
Solution Approach 1:
The container employs variable wall thickness with thicker sections at the bottom and heel areas to provide structural reinforcement where loads are concentrated, while maintaining thinner walls in less critical areas. This local quality variation allows weight reduction overall while preserving necessary structural rigidity at load-bearing locations.
Solution Approach 2:
The container design incorporates a tapered side wall configuration and angled shoulder geometry that utilize three-dimensional structural forms to achieve stacking efficiency and load distribution. The tapered walls and angled shoulders create geometric strength that compensates for reduced material thickness, allowing weight reduction while maintaining rigidity through dimensional optimization.
2Quantity of substance
If wall thickness is reduced to save material, then material usage is reduced, but top load capacity deteriorates
Solution Approach 1:
The container uses non-uniform wall thickness distribution with concentrated material at the bottom and heel regions where top loads are transmitted, while using less material in upper and lateral sections. This strategic material placement reduces overall material consumption while maintaining adequate top load capacity through localized reinforcement at critical stress points.
Solution Approach 2:
The container may utilize multi-layer or composite material construction that combines materials with different properties to achieve both reduced weight and maintained strength. The composite structure allows optimization of material placement and properties to satisfy both material reduction and load capacity requirements.
3Productivity
If container geometry is optimized for stacking, then stacking efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The container geometry is divided into distinct functional zones including a tapered side wall section, an angled shoulder section, and a brim section. This segmentation allows each zone to be optimized for its specific function (stacking, load bearing, dispensing) while using standardized manufacturing processes for each segment, balancing stacking efficiency with manufacturability.
Solution Approach 2:
The container employs specific geometric parameters such as tapered wall angles and shoulder angles that are optimized to achieve interlocking stacking configurations. These parameter optimizations enable efficient stacking while remaining compatible with standard thermoforming or injection molding processes, avoiding excessive manufacturing complexity.
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 design achieves a significant reduction in weight while maintaining a top load rating of at least 100 lbs, enabling efficient shipping and stacking with reduced material costs and increased structural rigidity.
Implementation Method 1
thermoforming the sheet of material into a container having a depth in the range of about 6'' to about 8''
Data Source
AI summary
A container has a side wall thickness profile sufficient for withstanding loads such as a top load, a package including the container and a lid, and methods and systems related to the container, are disclosed.