Tray System with Coaxial Receptacles for Stable Bottle Transport
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Solution Overview
Problem
Conventional pallets and slip sheets are inefficient for storing and transporting bottled water due to instability, damage from shifting, and the need for securing straps or plastic wrap, which adds time and cost, and are unsuitable for automated stacking and display.
Innovation Solution
A tray system with vertically stacked units that include upper and lower receptacles aligned coaxially, featuring a frustoconical-shaped enclosure and elastomeric cushioning to secure bottles without external securing means, allowing for stable and automated loading and display.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If bottles are stacked on traditional pallets and slip sheets, then bottles can be transported in bulk, but bottles are prone to shifting and tipping over during transport
Solution Approach 1:
The system divides the stack into discrete units by placing individual bottles into separate receptacles within trays. Each receptacle acts as an independent compartment that holds one bottle, preventing lateral movement while maintaining bulk transport capability through multiple receptacles per tray.
Solution Approach 2:
Trays containing multiple receptacles are stacked vertically, with each tray nesting within the structure of trays above and below it. The receptacles within each tray are arranged to fit together efficiently, creating a nested configuration that maximizes space utilization while maintaining stack stability.
2Stability of the object's composition
If bottles are secured with straps or plastic film on traditional pallets, then shifting is prevented, but time and cost increase due to additional securing operations
Solution Approach 1:
The receptacles are pre-formed as integral parts of the tray structure during manufacturing, rather than being added as separate securing components during loading operations. This preliminary integration eliminates the need for time-consuming strap application or plastic film wrapping at the point of use.
Solution Approach 2:
The receptacle structure automatically secures bottles through its geometric design and positioning features, without requiring external securing mechanisms. The receptacles are shaped and positioned to self-align and hold bottles in place through friction and geometric constraints inherent in the tray design.
3Quantity of substance
If bottles are stacked on traditional pallets, then bulk transport is achieved, but bottles experience excessive stress on spouts and caps leading to breakage
Solution Approach 1:
Each receptacle is designed with localized support features that distribute weight and stress away from vulnerable bottle components. The receptacles provide cushioning material or shaped surfaces that contact the bottle body rather than the cap or spout, and include reinforcement structures at specific locations to prevent stress concentration on critical bottle parts.
4Ease of operation
If conventional wood pallets are used for display, then bottles can be presented to customers, but broken planks and splintered surfaces detract from display quality
Solution Approach 1:
The tray system replaces traditional wood pallets with disposable or easily replaceable plastic trays that maintain consistent appearance and structural integrity throughout their service life. These trays are manufactured to uniform specifications without the wear, tear, and structural failures characteristic of wooden pallets, ensuring consistent display quality.
5Productivity
If traditional pallets with flat surfaces are used, then bottles can be placed on them, but automated stacking becomes difficult due to lack of target areas
Solution Approach 1:
The receptacles incorporate visual indicators such as colored markers, contrasting surface areas, or reflective elements that provide clear visual targets for automated loading equipment. These visual cues enable robotic systems and automated conveyors to accurately locate and position bottles within each receptacle, facilitating high-speed automated stacking operations.
Data Source
AI summary
A tray system includes a first tray having a plurality of stacking units. In one embodiment, each stacking unit forms a lower receptacle for receiving a neck portion of a first bottle, and an upper receptacle for receiving a base portion of a second bottle to be stacked above the first bottle. The lower receptacle has a first end, a second end opposite the first end, and a sidewall connecting the first end with the second end. The first end forms an opening for receiving a neck of a first bottle into the lower receptacle. The sidewall has a taper that prevents racking. The tray system may also include a second tray and a pallet.