Storage Basket with Integral Expanded Metal Mesh Frame
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Solution Overview
Problem
Existing storage basket designs require costly and difficult-to-manufacture end frames and top frame portions with weak structural connections, sharp edges that can cause injuries and rust easily, leading to reduced strength and durability.
Innovation Solution
A storage basket design featuring a bottom meshwork and side meshwork with expanded metal mesh elements formed by die stamping a single solid metal plate, where the top frame portion and meshed portion are integrally formed, eliminating the need for separate frames and reducing material usage while enhancing structural strength and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate end frames and top frame portions are used to assemble the storage basket, then the structure can be formed, but the manufacturing cost increases and manufacturing difficulty increases
Solution Approach 1:
The patent combines the end frame and top frame portion into a single integrated frame structure. The frame is formed as one continuous piece that simultaneously serves as both the end frame and top frame portion, eliminating the need for separate components and assembly operations. This merging reduces manufacturing complexity and cost while maintaining structural integrity.
Solution Approach 2:
The frame is designed with segmented functional zones within a unified structure. The single frame structure contains distinct regions that perform different functions (end frame functions and top frame functions) without requiring physical separation into multiple components. This allows the frame to be manufactured as one piece while still providing the structural benefits of differentiated zones.
2Loss of substance
If separate end frames and top frame portions are used, then the structure can be assembled, but material consumption increases
Solution Approach 1:
By merging the end frame and top frame portion into a single continuous frame structure, the patent eliminates the material required for connection joints, fasteners, and overlapping sections between separate components. The unified structure uses material only where structurally necessary, reducing overall material consumption while maintaining assembly capability.
3Strength
If separate end frames and top frame portions are clamped together, then the structure can be formed, but the connection strength is weak
Solution Approach 1:
The frame is manufactured as a single continuous piece of metal, eliminating weak clamped connections between separate components. The unified structure provides continuous material flow and inherent structural strength without relying on fasteners, welds, or clamps to join separate frame portions. This significantly enhances connection strength while simplifying manufacturing.
4Object-affected harmful factors
If the opening periphery is left unmodified with sharp edges, then manufacturing is simpler, but user safety is compromised and rust resistance decreases
Solution Approach 1:
The frame incorporates rounded corners and curved transitions at the opening periphery instead of sharp edges. This curvature design eliminates safety hazards while maintaining manufacturing simplicity, as the rounded features are naturally formed during the metal forming process. The curved geometry also improves paint adhesion and rust resistance compared to sharp angular edges.
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
The design is easier and faster to manufacture, saves material, provides strong and durable construction, eliminates sharp edges for safety, and ensures a long-lasting product with improved handling and structural integrity.
Implementation Method 1
the expanded metal mesh is formed by using die stamping to expandedly mesh a solid metal plate
Data Source
AI summary
A storage basket is provided, including a bottom meshwork and a side meshwork. The side meshwork formed with at least one mesh element extends transversely and upwardly from and surrounds the bottom meshwork. Each mesh element is an expanded metal mesh and includes a top frame portion disposed at a top end and a meshed portion located between the bottom meshwork and the top frame portion, and the expanded metal mesh is formed by using die stamping to expandedly mesh a solid metal plate. The top frame portion and the meshed portion of each mesh element are formed integrally.