Interlocking Packaging Tray for Rigid Device and Accessory Support
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Solution Overview
Problem
Existing packaging trays lack structural integrity, require manual retention during assembly, and often necessitate separate inserts for securing accessories, leading to inefficiencies and increased costs.
Innovation Solution
A packaging tray with interlocking sidewalls that fold and engage via ribs and channels to create a stable support structure, integrating accessory spaces directly into the tray design, eliminating the need for manual retention and separate inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional packaging trays are used, then assembly is simple, but structural integrity is insufficient
Solution Approach 1:
The locking portions are integrated directly into the sidewall structures, merging the connection function with the sidewalls themselves. This eliminates the need for separate fasteners or retention mechanisms, thereby enhancing structural integrity without proportionally increasing assembly complexity
Solution Approach 2:
The interlocking sidewalls feature self-aligning locking portions that automatically engage during assembly. The rib and channel design allows the sidewalls to self-retain without manual intervention, providing self-service assembly that maintains simplicity while achieving strong structural integrity
2Reliability
If separate inserts are used for accessories, then accessories are secured, but device complexity and material costs increase
Solution Approach 1:
The sidewalls serve multiple functions: they provide structural support, create compartment definitions, and integrate accessory retention features through locking portions. This multi-functionality eliminates the need for separate accessory inserts, reducing overall packaging structure complexity while maintaining reliable accessory retention
Solution Approach 2:
The accessory retention function is merged into the sidewall structure itself through the locking portions. Instead of using separate inserts for accessories, the sidewalls directly provide retention capabilities, thereby reducing device complexity and material costs while ensuring reliable accessory retention
3Strength
If more material is used for structural integrity, then strength improves, but material costs and packaging footprint increase
Solution Approach 1:
The sidewalls are segmented into compartments with integrated locking portions that provide structural reinforcement at key locations. This segmented approach concentrates material where needed for strength while avoiding unnecessary material usage in non-critical areas, thereby maintaining structural stability without increasing overall material quantity
Solution Approach 2:
The locking portions and rib-channel interlocking features provide localized structural reinforcement where strength is most needed. This local quality approach enhances structural stability at critical joints without requiring increased material throughout the entire packaging tray, thus avoiding increased material costs and packaging footprint
Data Source
AI summary
A packaging tray configured to physically support an electronic device that includes a center panel, first and second opposing sidewalls, and first and second compartments. The center panel includes a first and second pairs of opposing fold edges, with the fold edges of the first and second pairs oriented substantially perpendicular to one another. The first opposing sidewall extends from a first fold edge, and the second opposing sidewall extends from a second fold edge, substantially perpendicular to the first opposing sidewall. A first compartment is defined in the first opposing sidewall and includes a first locking portion. A second compartment is defined in the second opposing sidewall and includes a second locking portion. The second locking portion is configured to engage the first locking portion to connect the first and second opposing sidewalls together. This provides enhanced structural integrity and allows for securing accessories.