Corrugated Two-Piece Shelf Assembly for Low-Cost Modular Display
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Solution Overview
Problem
Existing shelving display systems are costly and difficult to manufacture and set up, posing challenges in shipping and on-site installation.
Innovation Solution
A shelving display system formed from a blank of corrugated material with U-shaped cutouts, deflectable tabs, and slots, where shelves are created by folding and gluing components to form a stable and easy-to-assemble structure, using a combination of first and second shelf components with flanges and tabs to secure the shelves in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional shelving display systems are used, then structural stability is achieved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The shelving display is divided into multiple modular components including side walls, back wall, shelves, and support members that can be manufactured separately and assembled together. Each component is designed with standardized connection features (slots, tabs, flanges) that simplify assembly while maintaining structural integrity through the modular configuration.
Solution Approach 2:
Multiple functional elements are combined into integrated components. For example, shelves incorporate both support surfaces and positioning features (flanges with slots) in single pieces. The back wall integrates reinforcement panels and support member connections into one structural element, reducing the total number of separate parts while maintaining stability.
2Ease of operation
If complex shelving systems are used, then structural stability is improved, but ease of setup and shipping difficulty worsen
Solution Approach 1:
Connection features such as slots, tabs, and flanges are pre-formed during manufacturing. The reinforcement panels and support members are pre-attached to the back wall using adhesives or mechanical fasteners before shipping. This preliminary preparation allows for rapid on-site assembly without requiring complex field fabrication or adjustment.
Solution Approach 2:
The shelving system incorporates adjustable elements that allow configuration changes during setup. Support members can be positioned at different heights along the back wall, and shelves can be installed at various positions, enabling the structure to adapt to different assembly sequences and site conditions while maintaining structural integrity.
3Productivity
If integrated shelving components are used, then manufacturing efficiency is improved, but assembly flexibility and configuration options are reduced
Solution Approach 1:
Standardized connection features (slots in flanges, corresponding tabs) are designed to work across all shelf components regardless of their specific function or position. The same basic joint design is used for connecting shelves to side walls, back walls, and support members, simplifying manufacturing while allowing flexible configuration through different arrangement patterns.
Solution Approach 2:
The shelving system provides configuration flexibility through vertical and horizontal arrangement variations. Multiple support members can be positioned at different heights, and shelves can be installed at various positions along the dimensions, creating numerous configuration options from a standardized set of components manufactured using efficient, repeatable processes.
Data Source
AI summary
A shelving display formed from a blank of material including a plurality of shelves formed from a first shelf component and a second shelf component.