Interlocking Sheet Packing Structure for Stable 3D Shape
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Solution Overview
Problem
Conventional packing members formed from a single sheet material struggle to maintain their three-dimensional shape due to displacement of parts.
Innovation Solution
A packing member design featuring a floor, first side wall with a through-hole, and paired second side walls with projections and slits, where the projections and slits interlock to prevent displacement and maintain the three-dimensional shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a single sheet material is bent into a three-dimensional shape using conventional slits and cutouts, then the packing member can be manufactured simply, but the parts displace and the three-dimensional shape cannot be maintained firmly
Solution Approach 1:
The projection segments are inserted into the through-hole of the first side wall, creating a nested structure where one component fits within another. This nesting arrangement prevents displacement of the side walls while maintaining the three-dimensional shape, resolving the contradiction between shape stability and configuration simplicity.
Solution Approach 2:
The side walls are divided into separate segments (first side wall with through-hole, and second side walls with projection segments) that can be assembled together. This segmentation allows each part to be formed independently and then joined to prevent displacement, achieving stable three-dimensional shape maintenance without requiring complex monolithic structures.
2Reliability
If projection segments are inserted in the through-hole to prevent displacement, then the three-dimensional shape is maintained firmly, but the assembly process becomes more complex
Solution Approach 1:
The projection segments are designed to be inserted into the through-hole by the assembly process itself, where the geometry of the projection segments and through-hole guides proper alignment and insertion. This self-service mechanism ensures reliable displacement prevention while keeping the assembly process straightforward, as the components self-align during assembly.
3Strength
If the floor has a projection extending beyond the first side wall, then the structural integrity is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The projection on the floor is designed with specific local geometry that extends beyond the first side wall to provide structural reinforcement. This local quality enhancement at the projection area improves overall structural integrity without requiring high precision across the entire component, as the projection's specific geometry provides the necessary strength where needed.
Data Source
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AI summary
A packing member (1) formed by bending a single sheet material includes a floor (2), a first side wall (3), and a pair of second side walls (4). The first side wall (3) has a through-hole (3h) penetrating it in the first direction (D1). The pair of second side walls (4) have projection segments (4d) and slits (4e). The projection segments (4d) are inserted in the through-hole (3h) and project outward in the first direction (D1) beyond the first side wall (3). The slits (4e) are formed at a position adjacent to the outer surface of the first side wall (3) of the projection segments (4d) with the projection segments (4d) inserted in the through-hole (3h) and the slits have opening edges (4de) at the ends of the projection segments (4d) close to the floor (2) and extend in the direction away from the floor (2) up to a predetermined position.