Corrugated Shelf Assembly for Flat-Pack Display Strength
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Solution Overview
Problem
Existing shelving display systems are costly and difficult to manufacture, ship, and set up due to their complex structures.
Innovation Solution
A shelving display system formed from a single blank of corrugated material, where multiple 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 achieved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent combines multiple shelf components into a single integrated blank of corrugated material. The blank includes front walls, back walls, and shelf supports all formed from one continuous piece, eliminating the need for separate manufacturing and assembly of multiple structural components while maintaining structural integrity through the corrugated material's inherent strength.
Solution Approach 2:
The single blank is segmented into functional zones during the folding and assembly process. The blank contains pre-formed fold lines that divide it into front wall sections, back wall sections, and shelf support sections, allowing the structure to be divided into functional components without requiring separate physical parts.
2Stability of the object's composition
If traditional shelving display systems are used, then structural stability is achieved, but ease of manufacture and setup deteriorate
Solution Approach 1:
The blank is pre-configured with fold lines, cut lines, and attachment points during manufacturing. The shelf supports are pre-formed with tabs and slots, and the front and back walls are pre-cut to exact dimensions, allowing for rapid assembly without complex manufacturing steps or specialized tools at the assembly stage.
Solution Approach 2:
Multiple structural elements that would traditionally require separate manufacturing processes are combined into a single die-cut and folded blank, simplifying the manufacturing process to a single stamping and folding operation while maintaining structural stability through the integrated design.
3Force
If traditional shelving display systems are used, then load-bearing capacity is maintained, but shipping efficiency and cost increase
Solution Approach 1:
The shelf supports are designed to nest within the channels formed by the front and back walls. When the display is assembled, the shelf supports fit into recesses or channels in the walls, allowing the entire structure to be compacted into a flat package for shipping and then expanded to its full three-dimensional form at the point of use, reducing shipping volume while maintaining load-bearing capacity.
Solution Approach 2:
The display structure transitions from a flat, low-volume state during shipping to an expanded, high-volume state during use. The corrugated material and fold lines enable the structure to dynamically change its configuration, providing load-bearing strength when assembled while minimizing material volume during transport.
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.