Universal Tray Cover Structure for Depalletizer Suction Resistance
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Solution Overview
Problem
Current packaging and tray technologies, particularly for open top containers, are not compatible with automated depalletizing and repalletizing processes in distribution centers, leading to errors and inefficiencies in sorting and shipping.
Innovation Solution
A universal tray cover system that includes a container blank and lid blank, designed with specific features such as holes and fasteners to secure the lid to the container, allowing it to withstand depalletizer suction while enabling easy removal by retailers, and incorporating stacking flaps for efficient palletization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If open top trays are used for packaging, then ease of access and product visibility is improved, but compatibility with automated depalletizing machinery deteriorates
Solution Approach 1:
The tray system is divided into separate components: an open top tray body and a removable lid. This segmentation allows the tray to maintain open accessibility while the lid can be added to provide compatibility with automated depalletizing machinery. The lid is attached using fasteners that secure it to the tray body, creating a functional combination that satisfies both requirements.
Solution Approach 2:
The lid is designed to be removable and reattachable, providing dynamic functionality. When the lid is attached, the tray becomes compatible with automated machinery; when removed, accessibility is improved. This dynamic configuration allows the same tray to adapt to different operational requirements throughout the supply chain.
2Adaptability or versatility
If trays are redesigned to be compatible with automated machinery, then compatibility with automated depalletizing is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The lid is designed as a universal component that can be attached to various tray bodies, providing multi-functionality. The same lid design can work with different tray configurations, and the fastening mechanism is standardized to accommodate multiple tray types. This universality reduces the need for complete tray redesigns while maintaining compatibility with automated machinery.
Solution Approach 2:
The lid acts as an intermediary component between the existing tray and the automated depalletizing machinery. Rather than modifying the tray itself, the lid serves as a mediator that interfaces with the machinery, allowing existing trays to be used while achieving compatibility with automated systems.
3Ease of operation
If traditional hand pick warehouses are used for open top containers, then ease of handling is maintained, but productivity and automation capability deteriorate
Solution Approach 1:
The tray configuration dynamically adapts to different handling requirements. Open top trays provide ease of handling for manual operations, while the same trays with attached lids enable automated depalletizing and repalletizing operations. This dynamic configuration allows the system to transition between manual and automated processing modes.
Solution Approach 2:
The tray system provides multi-functionality by supporting both manual handling operations and automated machinery operations. The removable lid feature allows the tray to serve multiple functions: open for manual access, closed for automated processing, and configurable for different stacking requirements in automated repalletizing operations.
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
Enables seamless integration with automated distribution center machinery, preventing product loss or distortion during handling and allowing for efficient stacking and shipping without requiring redesign of existing containers.
Implementation Method 1
a fastener configured to secure the lid to the container. The fastener includes a body portion and a fastening portion
Implementation Method 2
automated depalletizing and repalletizing processes in distribution centers
Data Source
AI summary
In accordance with at least one aspect of this disclosure, a blank for forming a lid for covering a container holding product therein, comprises, a top panel, a first lid side flap foldably connected to the top panel at a first top panel fold line, and a second lid side flap foldably connected to the top panel, opposite the first side, at a second top panel fold line. With the lid constructed, the first lid side flap and second lid side flap are configured to be inserted into a set up container such that the first lid side flap abuts a first side panel of the set up container and the second lid side flap abuts the second side panel of the set up container to allow additional containers to be stacked atop the lid panel without crushing the product within the interior space of the set up container. Further, when constructed and inserted into the set up container, the lid is configured to interact with the container in such a manner so as to resist upward movement exerted onto the lid by a depalletizer vacuum to prevent the lid from being removed from the container by the depalletizer.