Flat-Pack Fireplace Insert Assembly With Shared Width Components

Solution Overview

Problem

The closed box construction of simulated fireplace inserts increases shipping costs due to empty volume, making it challenging for manufacturers and retailers to reduce delivery costs effectively.

Innovation Solution

A ready-to-assemble simulated fireplace insert kit that breaks down into individual components for easier packing and shipping, allowing for a flat format that can be combined with a ready-to-assemble furniture kit, utilizing shared components across different widths to reduce manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If simulated fireplace inserts are manufactured as sealed or welded box units, then structural integrity is improved, but shipping volume and delivery costs increase

Engineering Contradiction:

Improvestructural integrityVSAvoidshipping volume

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The fireplace insert is divided into multiple separate components including side panels, top panel, bottom panel, back panel, and various structural elements that can be shipped individually in a flat-pack format. These segmented components are then assembled by the end user to form the complete fireplace insert, reducing shipping volume while maintaining the structural integrity of the final assembled product.

Inventive Principle:

Principle #1Segmentation

2Ease of operation

If fireplace inserts are provided as complete box units, then assembly simplicity is improved, but manufacturing and shipping costs increase

Engineering Contradiction:

Improveassembly simplicityVSAvoidmanufacturing cost

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The fireplace insert is divided into multiple separate components including side panels, top panel, bottom panel, back panel, and various structural elements that can be shipped individually in a flat-pack format. These segmented components are then assembled by the end user to form the complete fireplace insert, reducing shipping volume while maintaining the structural integrity of the final assembled product.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The individual components are pre-cut, pre-drilled, and pre-prepared with attachment mechanisms during manufacturing, so that the final assembly step requires minimal effort from the end user. This preliminary preparation maintains ease of assembly while enabling the cost and volume benefits of segmented construction.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If different width fireplace inserts are manufactured separately, then customization options are improved, but manufacturing volume and cost efficiency decrease

Engineering Contradiction:

Improvewidth customizationVSAvoidmanufacturing efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The fireplace insert design uses a universal set of components including standard side panels, top panels, bottom panels, and structural elements that can be configured to create multiple different width versions of the fireplace insert. This modular component system allows a single production run to supply parts for various width configurations, improving manufacturing efficiency while maintaining product versatility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20220299210A1Ready to assemble simulated fireplace insert system with shared components

Publication Date: 2022.09.22 LIVING STYLE B V I LTD

AI summary

The present disclosure provides a novel ready to assemble simulated fireplace insert kit which can be combined with a pre-built furniture piece, or a ready to assemble furniture piece to provide a unique solution in the ready to assemble furniture product category. The ready to assemble simulated fireplace insert is broken down into individual components that can more easily be packed and shipped in a flat format and assembled by the end user. In some embodiments, certain components may be shared across different width insert assemblies to reduce costs.