Compact Deck Box Kit Using Nested Homogeneous Panels
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Solution Overview
Problem
Conventional deck boxes require large, elongated shipping containers due to dissimilarly sized wall panels, leading to inefficient storage and increased shipping costs, as well as gaps that need filling with packing material.
Innovation Solution
The use of injection molded plastic panels that interlock to form a deck storage box with integral cross-bracing, ribs, and gussets, allowing for a compact, nested configuration with square packaging, eliminating air voids and requiring minimal hardware for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional dissimilarly sized wall panels are used to form a deck box, then the deck box can be assembled to form a rectangular storage container, but the packaging requires large elongated shipping containers with air space that increases shipping costs
Solution Approach 1:
The patent applies homogeneity by making all wall panels substantially the same size and shape (rectangular with identical dimensions). This allows the panels to be neatly stacked and nested in a compact square configuration, eliminating the air space problems associated with dissimilarly sized panels and reducing shipping container volume requirements.
Solution Approach 2:
The patent implements nesting by designing the wall panels to be stackable and nestable in a compact configuration. The panels can be placed one inside another or stacked in an organized manner that minimizes the overall packaging volume, transforming the shipping from large elongated containers to compact square containers.
2Shape
If dissimilarly sized wall panels are used in conventional deck boxes, then the panels can form a rectangular shape, but packing material is required to fill dead air space
Solution Approach 1:
By making all wall panels substantially the same size and rectangular shape, the patent eliminates the dead air space that occurs when dissimilarly sized panels are packaged together. This homogeneous configuration allows panels to fit tightly together without requiring additional packing material to fill gaps.
3Length of stationary object
If oblong shipping cartons are used for conventional deck boxes, then the panels can be packaged, but storage and shipping costs increase due to length
Solution Approach 1:
The patent uses nesting to reduce the length of shipping cartons by allowing panels to be stacked and nested in a compact square configuration rather than requiring long elongated containers. This dramatically reduces the length dimension of the packaging.
Solution Approach 2:
The patent transitions from linear/elongated packaging to a more three-dimensional compact square configuration. By changing how the panels are arranged in space (from extended linear arrangement to compact stacked arrangement), the length dimension is significantly reduced while maintaining all necessary panels.
Data Source
AI summary
A deck box kit formed from injection molded split plastic panels that interlock with an adjoining panel to form top, bottom, front and rear walls. The adjoining panels are secured in position with screw fasteners, and utilize integrally formed cross bracing, ribs and gussets for increased rigidity. In a disassembled state, the panels are substantially the same size, allowing efficiency in storage and reduced shipping costs by employing substantially square packaging. Further, the panels are stored in a nested configuration to eliminate the shipping of containers requiring fillers to address free air space.