Stackable Container with Recessed Base for Pallet Space Optimization
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Solution Overview
Problem
Plastic containers face challenges in stacking stability due to the weight distribution issue, requiring segregation sheets to prevent instability, and they do not efficiently utilize pallet space during transportation, leading to increased costs and waste.
Innovation Solution
Design of plastic containers with a recessed portion in the base and undulating surfaces on the top and base, allowing for multiple discrete contact points when stacked, which distributes weight evenly and eliminates the need for segregation sheets, and optimizing the shape to maximize pallet space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If containers are stacked with higher vertical extension necks to allow easy lid placement, then ease of operation is improved, but stacking stability deteriorates due to weight concentration on the shoulder
Solution Approach 1:
The base is segmented into a recessed portion that receives the upper container's neck, creating a nested arrangement. This segmentation allows the weight to be distributed to the base rather than concentrated on the shoulder, resolving the stacking stability issue while maintaining the extended neck for easy lid placement.
Solution Approach 2:
The patent eliminates the need for disposable segregation sheets between stacked containers. The recessed base structure provides inherent stability without requiring additional disposable materials, reducing waste and cost while maintaining stacking stability.
2Ease of manufacture
If traditional container designs are used, then manufacturing simplicity is maintained, but pallet space utilization deteriorates due to inefficient stacking
Solution Approach 1:
The upper container's neck is nested within the recessed portion of the base below, creating a nested doll arrangement. This nesting eliminates wasted space between containers and allows tighter stacking on pallets, significantly improving space utilization while maintaining manufacturing simplicity through the blow-molding process.
Solution Approach 2:
The design utilizes the vertical dimension by creating a recessed portion in the base that receives the neck of the upper container. This dimensional change allows containers to stack more efficiently in the vertical space on pallets, improving overall space utilization without complicating the manufacturing process.
3Strength
If more material is used to strengthen the container neck and shoulder, then strength is improved, but weight increases leading to higher transportation costs
Solution Approach 1:
The base is segmented with a recessed portion that provides structural support for the stacked container's neck. This segmentation allows the weight-bearing function to be distributed to the base rather than requiring additional material in the neck and shoulder areas, maintaining strength while minimizing weight.
Solution Approach 2:
The design changes the geometric parameters of the base by adding a recessed portion, rather than increasing material thickness in the neck and shoulder. This parameter change provides the necessary structural support through geometry rather than material quantity, reducing overall container weight while maintaining strength.
Data Source
AI summary
A container which includes a recessed portion and a complimentary top and base of generally undulating design which allow for a stack of such containers to be arranged where the neck of a lower container is placed within the recessed portion of an upper container and the base of the upper container contacts the top of the lower container. The container stack can then be extended to comprise multiple stacks which are positioned on a shipping pallet to provide for improved transportation efficiency of palletized containers.