Universal Shipping and Display Container with Accordion Bridge
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Solution Overview
Problem
Current PDQ packaging processes are inefficient in terms of component manufacturing and supply chain management, as they are often tailored to specific shelf sizes and require extensive labor for assembly and customization, leading to suboptimal compliance and product visibility in retail stores.
Innovation Solution
The development of a universal shipping and display container system featuring accordion-foldable bridge elements and customizable tray designs, which can be easily adapted to various product sizes and shapes, reducing the number of components needed and streamlining the manufacturing and supply chain processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional PDQ packaging is designed for specific shelf sizes, then it provides precise fit for targeted retail displays, but it requires multiple different packaging designs and increases manufacturing complexity
Solution Approach 1:
The display container is designed with adjustable shelf support members that can be positioned at multiple locations, allowing a single container design to fit different shelf sizes. The container includes a base tray, vertical side walls, and adjustable shelf supports that can be configured to accommodate various retail display requirements, eliminating the need for multiple specialized container designs.
Solution Approach 2:
The shelf support members are made movable and adjustable rather than fixed, allowing the container structure to adapt dynamically to different shelf configurations. The adjustable supports can be repositioned along the side walls to match different shelf heights and depths, providing flexibility across multiple retail environments.
2Adaptability or versatility
If extensive labor is used for assembly and customization of PDQ packaging, then complex packaging designs can be implemented, but labor costs and assembly time increase significantly
Solution Approach 1:
The display container is divided into separate modular components including a base tray, vertical side walls, adjustable shelf support members, and removable product holders. These segmented components can be independently manufactured and then quickly assembled on-site, reducing both manufacturing complexity and assembly time while maintaining customization capability.
Solution Approach 2:
The container design allows for easy self-assembly by retail personnel without requiring specialized tools or extensive training. The modular components are designed to connect through simple mechanisms that enable quick assembly and disassembly, empowering store employees to set up displays independently and reducing reliance on external assembly services.
3Reliability
If protective packaging is added to insure displays arrive undamaged, then product protection during shipping is improved, but the physical size and shipping cost increase
Solution Approach 1:
The container design incorporates built-in protective features such as recessed areas for product insertion, interlocking components that secure parts together during transit, and structural reinforcement at key stress points. These beforehand protective measures are integrated into the container structure itself, eliminating the need for additional external protective packaging materials.
Solution Approach 2:
The protective functions are merged into the primary container structure rather than being separate add-on elements. The base tray, side walls, and support members are designed to provide both structural support and protection during shipping, combining multiple functions into a single integrated design that doesn't increase overall shipping volume.
4Adaptability or versatility
If multiple components are used in PDQ packaging, then functionality and adaptability are improved, but the number of parts to manufacture and assemble increases
Solution Approach 1:
Each component in the container design serves multiple functions. For example, the vertical side walls provide structural support, define the container boundaries, and serve as mounting surfaces for the adjustable shelf supports. The base tray holds products, provides structural foundation, and integrates with the support members. This multi-functionality reduces the total number of components needed while maintaining adaptability.
Data Source
AI summary
A shipping and display container includes, for example, a first tray element and a second tray element, each tray element having a tray element bottom panel and a tray element back panel, a bridge element disposed between the first and second tray elements, the bridge element having a first center panel and a second center panel. The first and second center panels are accordion-foldable between a first position confronting one another and a second position extending in a common plane. The shipping and display container further includes a cover element for covering a space between the first and second tray elements. The first tray element, the second tray element, the bridge element and the cover element are interconnected as a single unit, and no adhesive materials are required for assembling the container, and wherein all of the elements are integrally formed in a single blank or sheet.