Composite Tray Structure for High-Load Stacking Without Thicker Walls
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Solution Overview
Problem
The increasing quantity of stacked electronic products during delivery leads to higher friction and collision risks, necessitating thicker trays to support weight, which increases manufacturing costs and reduces loading efficiency.
Innovation Solution
A composite tray design with a tray body and an external supporting member, where the supporting member divides the accommodating groove into inner and outer spaces, allowing separate loading of objects on the loading plate and supporting plate, reducing the need for increased tray thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the bottom wall of the tray is increased to support the weight of stacked electronic products, then the load-bearing capacity is improved, but the manufacturing cost increases and the loading rate decreases
Solution Approach 1:
The tray body is divided into an inner tray and an outer tray, with the outer tray providing additional load-bearing support. This segmentation allows the system to support heavier loads without increasing the thickness of a single tray bottom wall, thereby maintaining manufacturing efficiency while improving load capacity.
Solution Approach 2:
The composite tray combines two separate tray structures (inner tray and outer tray) into a unified load-bearing system. This composite structure distributes the weight of stacked electronic products across both trays, enabling the system to handle increased loads without requiring thicker individual tray components.
2Strength
If the thickness of the bottom wall of the tray is increased to support the weight of stacked electronic products, then the load-bearing capacity is improved, but the loading rate of the product is reduced
Solution Approach 1:
By segmenting the tray structure into inner and outer trays with distinct load-bearing functions, the design enables efficient stacking of electronic products without requiring excessive tray thickness. This maintains compact dimensions for high loading rates while providing sufficient load support capacity.
3Productivity
If the quantity of electronic products being stacked is increased to improve loading efficiency, then the loading rate is improved, but the risk of friction or collision between products increases
Solution Approach 1:
The inner tray and outer tray create distinct loading zones that can accommodate different quantities of electronic products. This segmentation allows optimized stacking arrangements that reduce friction and collision risks while maintaining high loading rates.
Solution Approach 2:
The outer tray acts as a protective structure that cushions and absorbs forces during stacking and transport. This beforehand cushioning reduces the impact of friction and collision between stacked electronic products, enabling safer high-density stacking.
Data Source
AI summary
A composite tray includes a tray body and an external supporting member. The tray body includes a loading plate and a plurality of side walls. The side walls protrude from the loading plate. The side walls and the loading plate jointly form an accommodating groove, and the accommodating groove has an opening. The external supporting member includes a supporting plate and a plurality of assembly members. The supporting plate is located in the accommodating groove and divides the accommodating groove into an inner space and an outer space. The inner space is located between the supporting plate and the loading plate. The outer space is located between the opening and the supporting plate. The assembly members are connected around the supporting plate and respectively assembled to the side walls, and a thickness of the supporting plate is less than a thickness of the loading plate.