Folding Utility Rack End Supports for Compact Shipping

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Solution Overview

Problem

Existing shelving systems face challenges with large packaging sizes due to rigid end supports, requiring substantial storage space and increased costs, while unassembled systems are cumbersome to assemble and may lack stability.

Innovation Solution

A utility rack with bolted end supports featuring folding cross members that can be collapsed for compact storage and easily assembled using fasteners, allowing for independent shelf placement and enhanced stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If end supports are fabricated as unitary welded structures, then strength and rigidity are improved, but packaging size and storage space requirements increase

Engineering Contradiction:

Improvestrength and rigidityVSAvoidpackaging size

Core Design Contradiction:

StrengthVSVolume of stationary object

Solution Approach 1:

The end support is divided into separate components: vertical supports and cross members that can be disconnected. The cross members can be detached from the second vertical support, allowing the components to be collapsed or nested together for compact packaging while maintaining the welded construction quality for strength when assembled

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The end support structure transitions from a static fixed configuration to a dynamic collapsible configuration. The cross members are designed to be movable between an extended position for use and a collapsed position for storage, enabling the structure to adapt its volume while maintaining structural integrity when deployed

Inventive Principle:

Principle #15Dynamics

2Volume of stationary object

If end supports are produced as entirely disassociated individual members, then packaging size is reduced, but assembly time and difficulty increase

Engineering Contradiction:

Improvepackaging sizeVSAvoidassembly time

Core Design Contradiction:

Volume of stationary objectVSLoss of time

Solution Approach 1:

The cross members are pre-attached to the first vertical support through welding before shipping. This preliminary action reduces the number of components the purchaser must assemble and eliminates the need for precise alignment during assembly, as the cross members are already positioned correctly on one end

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If pin and slot connectors are used for disassociated members, then ease of assembly is improved, but stability and rigidity deteriorate due to play and misalignment

Engineering Contradiction:

Improveease of assemblyVSAvoidstability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The connection system is segmented into two distinct functions: permanent welded connections at the first vertical support for structural integrity, and removable fastener connections at the second vertical support for assembly/disassembly. This segmentation allows each connection type to be optimized for its specific purpose

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of using pin-and-slot connectors that require precise alignment, the invention uses fasteners that replicate the connection function without the alignment constraint. The fastener system copies the structural connection capability while eliminating the harmful alignment sensitivity

Inventive Principle:

Principle #26Copying

4Device complexity

If shelf supports are used as connector members for end supports, then device complexity is reduced, but adaptability deteriorates as shelf locations are limited

Engineering Contradiction:

Improvedevice complexityVSAvoidshelf placement flexibility

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The system is segmented into dedicated structural components (cross members for end support) and dedicated shelf support components (adjustable shelf supports). This separation allows shelf supports to be independently positioned at multiple locations along the vertical supports without being constrained by the end support structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The vertical supports serve multiple functions: they provide structural support for the end supports through welded cross members, and simultaneously provide adjustable mounting locations for shelf supports at various heights. This multi-functionality increases adaptability without adding complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS9924797B2Utility rack having end supports with folding cross-members

Publication Date: 2018.03.27 JS PROD INC

AI summary

A utility rack includes a pair of end supports for supporting one or more shelves there between. Each end support includes a first vertical support having one or more cross members mounted thereto and a second vertical support. The cross members may be mounted to one or more cross member mounts of the first vertical support and are configured to be movable relative to the first vertical support between a stored position in which they are disconnected from the second vertical support and are collapsed inwardly towards the first vertical support for storage or transport and an extended position in which free ends of the cross members may be attached to the second vertical support using fasteners.