Folding Utility Rack End Supports for Compact Shipping and Rigidity
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Solution Overview
Problem
Existing shelving systems face challenges with large packaging sizes due to rigid end supports, which increase storage and shipping costs, and require time-consuming assembly with unassembled systems, often resulting in instability and reduced strength.
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 shelves to be positioned independently without serving as cross-supports.
Engineering Contradictions & Design Principles
Engineering 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
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 folded against the vertical supports and secured with straps, allowing compact packaging while maintaining structural integrity when assembled.
Solution Approach 2:
The cross members are designed to be movable relative to the vertical supports through folding joints, transitioning from a compact stored position to an extended operational position. This dynamic configuration allows the structure to adapt between compact storage and full strength deployment.
2Strength
If end supports are fabricated as unitary welded structures, then strength and rigidity are improved, but ease of storage and transportation deteriorates
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 folded against the vertical supports and secured with straps, allowing compact packaging while maintaining structural integrity when assembled.
Solution Approach 2:
The cross members are designed to be movable relative to the vertical supports through folding joints, transitioning from a compact stored position to an extended operational position. This dynamic configuration allows the structure to adapt between compact storage and full strength deployment.
3Volume of stationary object
If unassembled end supports with pin and slot connectors are used, then packaging size is reduced, but stability and strength deteriorate due to play between members
Solution Approach 1:
The cross members are designed to be movable relative to the vertical supports through folding joints, transitioning from a compact stored position to an extended operational position. This dynamic configuration allows the structure to adapt between compact storage and full strength deployment.
4Ease of manufacture
If unassembled end supports require purchaser assembly, then manufacturing complexity is reduced, but assembly time and difficulty increase
Solution Approach 1:
The cross members are pre-attached to the vertical supports in a folded configuration and secured with straps during manufacturing. This preliminary assembly reduces the complexity of final assembly while maintaining compact packaging, as the components arrive pre-configured and require minimal assembly steps.
Data Source
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.