Collapsible Crate Swing Bar Assembly
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Solution Overview
Problem
Traditional collapsible crates face inefficiencies in space usage during transport, as they require increased labor and handling complexity due to separate elements, which are less convenient and occupy the same volume when empty or full, leading to costly transportation issues.
Innovation Solution
A collapsible crate design featuring a swing bar pivotably connected to the end wall, engaged with side walls, that automatically transitions between erected and collapsed configurations, providing stability and support, with guide channels and stoppers to facilitate easy stacking and handling, reducing the need for additional manual input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If collapsible crates disassemble into separate elements, then volume efficiency during transport is improved, but handling convenience and operational simplicity deteriorate
Solution Approach 1:
The crate is divided into a base and four wall panels that can be separated and folded independently. Each wall panel is hinged to the base, allowing the crate to disassemble into manageable segments for compact transport while maintaining ease of reassembly through the hinge mechanism.
Solution Approach 2:
The crate incorporates dynamic hinge mechanisms that allow smooth transition between assembled and disassembled states. The hinges enable the wall panels to rotate and fold automatically, reducing manual effort required for collapse and assembly while maintaining structural integrity during both states.
2Strength
If traditional single-piece crates are used, then structural strength is improved, but space efficiency during empty transport deteriorates
Solution Approach 1:
The single-piece crate is segmented into modular components (base and hinged wall panels) that can be folded flat for transport. The segmentation maintains strength through rigid panel materials and reinforced hinge connections while enabling compact storage when empty.
Solution Approach 2:
The wall panels are designed to fold nested against the base structure, with each panel collapsing into a compact configuration that minimizes the overall volume occupied during transport, similar to a nested doll structure.
3Volume of moving object
If multiple separate elements are used for collapsible crates, then volume efficiency is improved, but the number of components and labor requirements increase
Solution Approach 1:
The crate design merges the base and wall panels into a unified structure through hinge connections, reducing the number of separate components that would otherwise require individual handling. The hinges integrate the panels into a single collapsible unit that moves as one assembly during folding and unfolding.
Solution Approach 2:
The hinge mechanisms are pre-installed and pre-configured during manufacturing, so that the crate requires minimal assembly effort when deployed. The preliminary attachment of hinges during production eliminates the need for complex field assembly operations.
Data Source
Figure 1
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AI summary
A collapsible crate includes a base, at least one side wall, at least one end wall, and at least one swing bar assembly. The side wall extends in a longitudinal direction and is hingedly attached to the base such that the side wall is movable between an erected configuration and a collapsed configuration. The top wall includes a top edge and an inner face and may include at least one of a guide channel, a stopper, and/or a locking feature. The end wall extends in a transverse direction and is hingedly attached to the base adjacent to the side wall and movable between an erected configuration and a collapsed configuration, wherein the end wall is adjacent to the side wall. The swing bar assembly is pivotably supported on the end wall and includes a swing bar that is engaged with the side wall.