Integrated Wheel Shield for Transportable Carton
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Solution Overview
Problem
Existing mattress cartons with fixed-axis wheels are difficult to manufacture and assemble cost-effectively due to their complex component structure, making it challenging to transport large and heavy mattresses efficiently.
Innovation Solution
A wheel assembly featuring an elongated injection molded thermoplastic shield with angled support flanges and wheel wells, integrated into the bottom rear corner of a corrugated cardboard carton, allowing for easier installation and use, with struts and nubs to secure the wheels and prevent shifting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If fixed-axis wheels are individually fastened to rigid strip members secured to carton corners, then the carton can be transported over surfaces, but the manufacturing and assembly process becomes complex and costly
Solution Approach 1:
The patent combines multiple previously separate components (wheel, axle, support structure, and carton corner reinforcement) into a single integrated wheel assembly unit. This consolidation maintains the transportation function while significantly simplifying the overall structure and reducing the number of individual parts that need to be manufactured and assembled separately.
Solution Approach 2:
The wheel assembly is designed to serve multiple functions simultaneously: it provides the rolling capability for transportation, reinforces the carton corner structure, and integrates the wheel mounting mechanism all within a single component system. This multi-functionality reduces the need for separate structural elements.
2Reliability
If multiple individual component parts are used for wheel assembly, then the wheels can be securely fastened, but the manufacturing and assembly cost increases
Solution Approach 1:
The patent merges the wheel mounting mechanism and support structure into an integrated assembly that can be installed as a single unit. This reduces the number of fastening operations and assembly steps required while maintaining secure wheel attachment, thereby lowering both manufacturing complexity and assembly costs.
3Ease of manufacture
If a simple wheel mounting structure is used, then manufacturing is easier, but the wheel assembly may shift during transport
Solution Approach 1:
The wheel assembly incorporates an asymmetric design where the support flanges extend at specific angles (40-45 degrees) and have different dimensions (front flange wider than rear flange). This asymmetric geometry provides inherent positional stability and prevents the assembly from shifting during transport, while still maintaining manufacturing simplicity through the use of standard injection molding processes.
Data Source
AI summary
A transportable carton assembly is disclosed that includes a carton defining a bottom rear corner edge portion having a pair of longitudinally spaced apart apertures formed therein, and an elongated shield retained within the bottom rear corner edge portion of the carton and including a pair of longitudinally spaced apart wheels positioned to extend through the longitudinally spaced apart apertures formed in the bottom rear corner edge portion of the carton for transporting the carton over a surface.