Corrugated Two-Piece Shelf Assembly for Low-Complexity Displays
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Solution Overview
Problem
Existing shelving display systems are costly and difficult to manufacture, ship, and set up due to their complexity.
Innovation Solution
A shelving display system formed from a single blank of corrugated material, where shelves are created by folding and interlocking first and second shelf components from separate wall segments, using a positioning panel and glue strips for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional shelving display systems are used, then structural strength and stability are improved, but manufacturing cost and complexity increase
Solution Approach 1:
The shelving display system is divided into multiple separate wall segments (front wall, back wall, side walls) that can be manufactured independently and then assembled together. Each wall segment contains pre-formed shelf components, allowing for modular construction that reduces overall system complexity while maintaining structural integrity through the interlocking assembly of segments.
Solution Approach 2:
The shelf components are extracted from traditional separate manufacturing processes and integrated directly into the wall segments during a single corrugated material forming process. This extraction of shelves as distinct elements and their integration into the wall structure simplifies the overall system by eliminating separate shelf installation steps while preserving strength.
2Stability of the object's composition
If traditional shelving display systems are used, then structural stability is improved, but ease of manufacture deteriorates
Solution Approach 1:
The manufacturing process merges the formation of wall segments and shelf components into a single integrated process using corrugated material. The corrugated material is formed to create both the structural walls and the shelf support elements simultaneously, eliminating multiple manufacturing steps and improving ease of manufacture while maintaining structural stability through the inherent strength of the corrugated construction.
3Force
If traditional shelving display systems are used, then load-bearing capacity is improved, but shipping efficiency deteriorates
Solution Approach 1:
The wall segments and shelf components are designed to nest within each other during shipping, with smaller elements fitting into spaces within larger components. This nesting arrangement dramatically reduces the shipping volume required to transport the display system components while maintaining the load-bearing capacity through the preserved structural integrity of the corrugated material construction.
4Reliability
If traditional shelving display systems are used, then structural integrity is improved, but setup time and complexity increase
Solution Approach 1:
The shelf components and wall segments are pre-assembled into integrated units during manufacturing, with connection points and alignment features prepared in advance. This preliminary action ensures structural integrity is established before shipping, and dramatically reduces setup time on-site as the pre-assembled units require minimal final assembly steps to achieve full structural integrity.
Data Source
AI summary
A shelving display system formed from a single blank of corrugated material. The display system including a plurality of shelves formed from a first shelf component and a second shelf component.