Convertible Reusable Shipping Crate With Tool-Free Stacking Gates
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Solution Overview
Problem
Existing metal shipping crates are not reusable, require hand tools for assembly and disassembly, lack adjustability for different vehicle sizes, and cannot be stacked efficiently due to weak hinges.
Innovation Solution
A collapsible, convertible, and reusable metal crate with a hinged connector and slotted locking plates that allows gates to pivot, enabling tool-free assembly and disassembly, adjustability for various vehicle sizes, and folding for space-efficient storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal crates are made reusable with heavy-duty hinges, then stacking capability is improved, but hinge weight and complexity increase
Solution Approach 1:
The hinge is divided into two separate components: a fixed hinge attachment on the crate body and a movable hinge attachment on the door. This segmentation allows the door to pivot for loading while maintaining structural integrity for stacking, resolving the contradiction between door operation and stacking capability.
Solution Approach 2:
A vertical frame member acts as an intermediary element that transfers vertical stacking loads away from the hinge connection. This mediator allows the hinge to perform door-pivoting function while the vertical frame member handles the stacking load, enabling both door operation and reliable stacking without requiring an overly complex heavy-duty hinge.
2Adaptability or versatility
If adjustable portions are added to metal crates for different vehicle sizes, then adaptability is improved, but structural strength and stacking capability deteriorate
Solution Approach 1:
The crate incorporates adjustable vertical frame members with telescopic sections that can be extended or retracted to accommodate different vehicle heights. This dynamic adjustability allows the same crate structure to adapt to various vehicle sizes while maintaining structural strength through proper engineering of the telescopic mechanisms and locking systems.
Solution Approach 2:
The adjustable vertical frame members serve multiple functions: they provide structural support for stacking, enable adjustment for different vehicle sizes, and maintain structural integrity. This multi-functionality allows the crate to be both adaptable and strong without requiring separate structures for each function.
3Strength
If hand tools are required for assembly and disassembly, then connection strength is improved, but ease of operation and time efficiency worsen
Solution Approach 1:
The crate employs self-locking mechanisms including cam-locked connectors and friction-fit joints that automatically secure connections when components are assembled. These self-service features eliminate the need for hand tools while maintaining strong connections, allowing workers to assemble and disassemble the crate quickly by simply pushing or pulling components together.
Solution Approach 2:
Traditional mechanical fastening systems requiring tools (screws, nuts, bolts) are replaced with tool-free connection mechanisms such as cam locks, bayonet mounts, and friction-fit joints. These substituted mechanisms provide comparable or superior connection strength while enabling tool-free operation, significantly improving assembly ease and time efficiency.
4Strength
If crates are made fully assembled for shipping, then structural integrity is improved, but storage space and return shipping efficiency worsen
Solution Approach 1:
The crate is segmented into modular components (base, walls, doors, roof) that can be easily connected and disconnected. This segmentation allows the crate to be collapsed by nesting components together or disassembling into compact bundles, dramatically reducing storage volume for return shipping while maintaining structural integrity when assembled.
Solution Approach 2:
The crate components are designed to nest within each other when collapsed, with smaller parts fitting into larger sections. This nesting arrangement minimizes the volume occupied during storage and return shipping while ensuring that the same components can be quickly reassembled into a structurally sound crate for outbound shipping.
Data Source
AI summary
The present invention generally relates to a convertible, collapsible and reusable shipping crate. The crate is convertible in that the same base can used with extendable gates or fixed gates to ship equipment of differing heights, lengths, and wheel bases. At least one end of the crate may operate as a gate on a hinge for the loading and unloading of motorized vehicles. The hinge is comprised of a slotted plate on each side to lock the gates into place for loading and to raise the gates upright once loading is completed. The slotted plate positions the gates in an upright, locked position to carry all the weight on the upright beams of the gate, rather than the hinges, thereby allowing multiple crates to be stacked. The slotted plates also allow each of the two gates to collapse inward and flat on the base for stacking during return. The gates, optional cross braces, and slotted plates all contain removable pins as connectors so that no hand tools are required for setup, operation, and breakdown of the crate. The crate is reusable many times.