Tray for Prismatic Honeycomb Structures with Segmented Support

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Solution Overview

Problem

Conventional trays for packing and transporting prismatic honeycomb structures are prone to damage due to collision during transportation, and using container boxes increases management costs and reduces loading efficiency, especially when stacking multiple layers.

Innovation Solution

A tray with corrugated plate-shaped placing portions and intervening walls that prevent adjacent prismatic honeycomb structures from contacting each other, allowing for multiple-stage stacking without applying load to the edges, and optionally using a cushion for added protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If conventional trays are used for packing prismatic honeycomb structures, then the structures are protected from collision during transportation, but the edges forming the contours of both end surfaces are easily damaged when stacked in multiple stages

Engineering Contradiction:

Improvecollision damage protectionVSAvoidedge strength during stacking

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The tray is divided into multiple functional regions: placing portions for supporting the honeycomb structures, intervening walls for preventing lateral collision, and non-placing portions that avoid contact with vulnerable edges. This segmentation allows each region to perform its specific protective function without causing edge damage during stacking.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The non-placing portions act as intermediary spaces that prevent direct contact between the tray and the vulnerable edges of the honeycomb structures. By designing these non-contact zones, the tray mediates the stacking process to avoid applying load to the edges while still providing overall structural support.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If container boxes are used to protect prismatic honeycomb structures during stacking, then edge damage is prevented, but management cost increases and loading efficiency per area is impaired

Engineering Contradiction:

Improveedge protection during stackingVSAvoidloading efficiency per area

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The tray integrates multiple protective functions that were previously separated: collision protection through intervening walls, edge protection through non-placing portions, and stacking support through placing portions. By merging these functions into a single tray design, the need for additional container boxes is eliminated, improving loading efficiency while maintaining edge protection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The tray serves multiple purposes simultaneously: it acts as a packing base, a protective barrier against collision, a stacking support structure, and an edge-protection device. This multi-functionality replaces the need for separate container boxes, reducing management costs and improving loading efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If prismatic honeycomb structures are stacked in multiple stages via the tray, then loading efficiency is improved, but the edges are easily damaged due to the weak cushioning function of the resin tray

Engineering Contradiction:

Improveloading efficiencyVSAvoidedge damage from stacking load

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The tray design applies different structural qualities to different regions: placing portions provide firm support for stable stacking, intervening walls provide collision resistance, and non-placing portions provide cushioning by avoiding contact. This local differentiation allows multiple-stage stacking to proceed efficiently while protecting edges from damage.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11168034B2Tray for prismatic honeycomb structure

Publication Date: 2021.11.09 NGK INSULATORS LTD

AI summary

A tray including a plate-shaped portion for arranging a plurality of prismatic honeycomb structures having an outer peripheral side surface and partition walls provided on an inner peripheral side of the outer peripheral side surface, the partition walls partitioning a plurality of cells forming flow paths from a first end surface to a second end surface, the plate-shaped portion including: a plurality of corrugated plate-shaped placing portions for placing the prismatic honeycomb structures with the outer peripheral side surface in contact with the placing portions; flat plate-shaped non-placing portions adjacent to each of the corrugated plate-shaped placing portions; and partition walls erected between adjacent corrugated plate-shaped placing portions to prevent the outer peripheral side surfaces of adjacent prismatic honeycomb structures from contacting each other.