Storage Tote Base Wall Ridges to Reduce Injection Warping
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Solution Overview
Problem
Plastic storage totes often warp during the injection molding process due to pressure and stress, affecting their appearance and stacking ability.
Innovation Solution
The storage tote design incorporates a central ridge and side ridges that bisect the base wall, distributing stress evenly and enhancing structural integrity, similar to a structural Roman arch, thereby reducing warping and deflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high pressure and stress are exerted on the storage tote during injection molding, then the plastic is properly formed, but warping and deflection occur in the base wall
Solution Approach 1:
The base wall is segmented into multiple regions by introducing a central ridge that divides it into two sections, and side ridges that further segment the structure. This segmentation allows each segment to independently manage stress during injection molding, preventing overall warping while maintaining structural integrity.
Solution Approach 2:
The invention transitions from a two-dimensional flat base wall to a three-dimensional structured base wall with raised ridges. This dimensional change creates additional structural support elements that resist warping forces during manufacturing and provide enhanced stacking capability without adding significant weight.
2Loss of substance
If the base wall is made thinner to reduce material usage, then production cost decreases, but warping resistance deteriorates
Solution Approach 1:
Instead of uniformly thickening the entire base wall, the invention applies localized thickness variations by creating raised ridges in specific areas. The central ridge and side ridges provide enhanced structural support where stress concentration occurs, while other areas of the base wall maintain thinner profiles to minimize material usage.
3Stability of the object's composition
If the storage tote structure is reinforced to prevent warping, then stacking ability improves, but device complexity increases
Solution Approach 1:
The invention merges multiple functions into the base wall structure. The central ridge and side ridges simultaneously provide warping resistance during manufacturing, enhance stacking stability, and create defined channels for material flow during injection molding. This integration achieves multiple benefits without adding separate components or complex assembly steps.
Data Source
AI summary
A storage tote includes a main body with a base wall and a plurality of side walls. The base wall has a center area, a central ridge, a first side ridge, and a second side ridge. The center area is bounded by the plurality of side walls. The central ridge bisects the base wall. In addition, the central ridge has a first wall, a second wall, and a third wall. The first side ridge and the second side ridge are disposed across the center area and oriented parallel to the central ridge. The first side ridge is spaced apart from the first wall of the central ridge, while the second side ridge is spaced apart from the second wall of the central ridge.