Fiber Board Tray for Vehicle Storage with Folded Edge Design

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Solution Overview

Problem

Existing vehicle storage trays made of resin, such as polystyrene foam, face challenges in expanding storage capacity and efficient transportation due to bulkiness and low component transportation efficiency.

Innovation Solution

A tray made from a fiber board with specific cuts and dimensions, allowing for folding and assembly without bonding, which increases storage capacity and transportation efficiency by using a fiber board with a thickness of 2 to 6 mm and tensile strength of 850 to 2150 N/25.4 mm, enabling expansion and stacking during transport.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If resin material (polystyrene foam) is used for the tray, then the tray structure is simple and easy to manufacture, but the storage capacity is decreased and component transportation efficiency is low due to bulkiness

Engineering Contradiction:

Improvetray manufacturing simplicityVSAvoidstorage capacity

Core Design Contradiction:

Ease of manufactureVSVolume of moving object

Solution Approach 1:

The patent changes the material parameter from resin (polystyrene foam) to fiber board, which has different physical properties including smaller thickness for the same strength. This parameter change enables both maintaining manufacturing simplicity and increasing storage capacity by reducing the tray's volume occupation while keeping structural integrity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses fiber board as a composite material alternative to resin, combining fibers with binding agents to create a material that offers both structural strength and space efficiency. This composite material approach resolves the contradiction by providing a tray that is both easy to manufacture and space-efficient

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If resin material (polystyrene foam) is used for the tray, then the tray structure is simple and easy to manufacture, but the component transportation efficiency is low

Engineering Contradiction:

Improvetray manufacturing simplicityVSAvoidcomponent transportation efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

By changing the material parameter from resin to fiber board, the tray achieves smaller thickness and better stackability. This enables efficient stacking during transportation, directly improving component transportation efficiency while maintaining ease of manufacture through similar production processes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The fiber board tray can be divided into multiple layers or sections that can be stacked efficiently during transportation. This segmentation approach allows for compact stacking arrangements, improving transportation efficiency while the modular structure remains easy to manufacture

Inventive Principle:

Principle #1Segmentation

3Stability of the object's composition

If fiber board with higher total weight and tensile strength is used, then the tray shape retention is improved, but the assembly difficulty increases due to excessive hardness

Engineering Contradiction:

Improvetray shape retentionVSAvoidtray assembly ease

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent optimizes the fiber board parameters to specific ranges: total weight of 450-1000 g/m2 and tensile strength of 850-2150 N/25.4mm. This precise parameter control ensures the fiber board has sufficient strength for shape retention while maintaining appropriate flexibility for easy assembly, resolving the contradiction between stability and ease of manufacture

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If fiber board with lower total weight and tensile strength is used, then the assembly ease is improved, but the tray shape retention becomes difficult

Engineering Contradiction:

Improvetray assembly easeVSAvoidtray shape retention

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The patent establishes minimum thresholds for fiber board properties: total weight of at least 450 g/m2 and tensile strength of at least 850 N/25.4mm. These parameter specifications ensure the fiber board maintains sufficient structural integrity for shape retention while remaining easy to assemble, preventing both extremes of too weak or too hard materials

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11458902B2Tray for vehicle storage space and manufacturing method of tray for vehicle storage space

Publication Date: 2022.10.04 TAKEHIRO CO LTD

AI summary

An object is to expand the capacity of storage of a luggage box and thereby to increase the efficiency of component transportation. A tray for vehicle storage space is formed from a fiber board that includes a bottom portion, side portions and flat portions extended from the side portions and that has a thickness of 2 to 6 mm, a total weight of 450 to 1000 g/m2, and a tensile strength of 850 to 2150 N/25.4 mm. The fiber board has linear first cuts provided on a surface side to divide boundaries between the side portions and the flat portions, linear second cuts provided on a rear face side to divide boundaries between the bottom portion and the side portions, linear third cuts provided on the surface side to fold back the side portions, and linear third cuts provided on the rear face side.