Flat-Pack Display Booth Assembly Using Tab-and-Slot Interlocking
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Solution Overview
Problem
Conventional signage and shelving systems for convention display booths are heavy, expensive, and time-consuming to set up, incurring significant costs for transportation, assembly, and disassembly, often requiring professional assistance.
Innovation Solution
A portable display system comprising lightweight, flat-pack components made from materials like honeycomb board or plywood, which can be assembled and disassembled without tools, using extending tabs and slots for interlocking, and are 100% recyclable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional signage and shelving systems are used, then structural strength and stability are improved, but weight and transportation cost increase
Solution Approach 1:
The display system is divided into multiple modular components including vertical supports, horizontal shelves, connecting elements, and base units. Each component is designed as a separate lightweight piece that can be independently transported and assembled, reducing the weight burden on any single transport operation while maintaining overall structural strength through the coordinated assembly of parts.
Solution Approach 2:
The patent employs composite construction methods combining lightweight materials (such as aluminum extrusions, engineered woods, or plastic composites) with strategic reinforcement elements. This allows the structure to achieve necessary strength and stability while minimizing overall weight compared to conventional solid wood or metal construction.
2Strength
If conventional shelving systems are used, then load-bearing capacity is improved, but assembly time and complexity increase
Solution Approach 1:
The system is segmented into pre-fabricated modules with standardized connection interfaces. Each module is designed to be self-contained with pre-drilled holes, pre-attached brackets, or pre-formed connecting elements, allowing rapid assembly through simple connection actions rather than complex construction procedures.
Solution Approach 2:
The connecting elements are designed to be self-aligning and self-securing, featuring mechanisms such as friction-fit joints, snap-connectors, or tool-free fastening systems. This allows the structure to assemble itself with minimal human intervention, eliminating the need for specialized tools or complex assembly procedures while maintaining load-bearing capacity.
3Reliability
If professional assembly services are hired, then assembly quality and reliability are improved, but cost increases
Solution Approach 1:
The system incorporates detailed assembly instructions, color-coded components, and foolproof connection mechanisms that enable non-professionals to assemble the display structure reliably. The self-service design includes features such as numbered assembly steps, illustrated guides, and intuitive connecting elements that guide the user through proper assembly without requiring professional knowledge or skills.
Solution Approach 2:
The patent employs parameter optimization in the connection design, using friction coefficients, geometric interlocking ratios, and material properties tuned to provide reliable connections that are simple enough for non-professionals to assemble correctly. The connection parameters are designed to be tolerant of minor assembly variations while ensuring structural integrity.
4Reliability
If heavy-duty materials are used, then durability and stability are improved, but portability and ease of transport worsen
Solution Approach 1:
By segmenting the display system into multiple lightweight components, each piece can be easily carried by one or two people, yet the assembled structure achieves durability through the cumulative effect of multiple reinforced connection points and distributed load paths across the entire structure.
Solution Approach 2:
The system uses composite materials and hybrid construction techniques combining lightweight frameworks with reinforced joints and strategic bracing. This allows individual components to remain portable while the assembled structure achieves durability equivalent to or exceeding conventional heavy-duty materials through optimized structural design.
Data Source
AI summary
The present disclosure relates to a portable display system, products which can be easily carried to display booth, quickly hand assembled and disassembled without tools, and repackaged for easy transportation on the return trip. In an embodiment, the system includes one or more of a signage stand, shelving, a podium, or even a wall. Each of these items are light weight and conveniently packaged in flat carry containers, and come with parts and pieces and assembly instructions for easily assembling and disassembling the items step-by-step. In another embodiment, the system includes flat parts and pieces that can be assembled together. Each part or piece includes at least one extending tab or slot which is configured to mate with one or more corresponding slots or extending tabs in another part or piece, such that the parts or pieces, when fully assembled form a finished article, such as a signage stand, shelving, a podium, or a wall.