Universal Platform for Bulk Bin Stacking Stability
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Solution Overview
Problem
Bulk bins made of materials like corrugated paperboard are not sufficiently rigid to support stacked tote boxes, leading to degradation or failure of the upper rim when subjected to repeated contact, which prevents further use in multi-stacking configurations.
Innovation Solution
A universal platform with a top wall and angled legs that attaches to the upper rim of the bulk bin, providing a stable surface for stacking without protrusions to prevent the object from descending into the bin and distributing weight evenly, allowing for the stacking of pallets or additional bulk bins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bulk bins are made of corrugated paperboard to reduce weight and cost, then manufacturing cost and weight are reduced, but stacking strength and rim durability are insufficient
Solution Approach 1:
The invention combines corrugated paperboard with a rigid platform structure to create a composite stacking system. The platform provides the necessary structural strength while the paperboard bulk bin maintains its lightweight and cost-effective properties. This composite approach allows the bulk bin to support stacked loads without requiring the entire bin to be made of heavy, expensive rigid material.
2Productivity
If bulk bins are stacked directly on top of each other to increase storage density, then productivity and space utilization are improved, but the upper rim of the lower bulk bin degrades or fails due to repeated contact
Solution Approach 1:
The rigid platform acts as an intermediary element between stacked bulk bins. It provides a durable interface that absorbs and distributes the contact forces during stacking operations, preventing direct damage to the paperboard rim of the lower bulk bin. This mediator structure enables repeated stacking cycles without degrading the bulk bin rim.
Solution Approach 2:
The invention introduces a horizontal platform dimension between the vertical stacking interfaces. By distributing loads across a broader horizontal area rather than concentrating forces at the rim contact point, the system reduces stress on the bulk bin rim and enables more reliable repeated stacking.
3Strength
If an upper rail or rim member is added to reinforce the bulk bin for stacking, then stacking strength is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention extracts the reinforcement function from the bulk bin itself and places it in a separate, dedicated platform structure. This allows the bulk bin to remain simple and easy to manufacture, while the platform independently provides the necessary stacking strength and rim protection.
4Stability of the object's composition
If protrusions are added to the top wall to prevent object descent, then stacking stability is improved, but the object may concentrate load on one point causing rim degradation
Solution Approach 1:
The rigid platform provides a locally optimized surface with appropriate friction characteristics and geometry to prevent object descent, while distributing loads across its entire lower surface area. This localized quality enhancement at the platform-object interface achieves stability without the harmful point load concentration that would occur with protrusions directly on the bulk bin rim.
Data Source
AI summary
A platform enables a bulk bin to have an object stacked thereupon, such as a pallet or another bulk bin. The platform includes first and second pairs of legs extending downwardly from a top wall. An upper planar surface of the top wall is devoid of any protrusions which extend thereabove. An outer leg of each pair is spaced from an inner leg of each pair, the outer and inner legs in each pair are parallel to each other, and each of the outer and inner legs extend at a 45-degree angle, or about a 45-degree angle, relative to a centerline of the platform. The platform is placed on an upper rim of the bulk bin such that the side wall(s) of the bulk bin are between the respective legs.