Reinforced Load Carrier Tray With Rib Openings for Heavy Loads
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Solution Overview
Problem
Existing load carriers, such as trays, require additional reinforcement beyond the standard rib structure for transporting heavy goods, necessitating the integration of reinforcement strips during production, which can be complex and inefficient.
Innovation Solution
The introduction of aligned openings within the intersecting ribs on the tray's underside allows for the simple and straightforward integration of reinforcement strips during injection molding, using a molding tool with cores that form recesses without requiring a perpendicular molding tool part, and utilizing elastic tongues for secure strip retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcement strips are added to enhance tray stiffness, then structural strength is improved, but manufacturing complexity increases
Solution Approach 1:
The injection molding cores are pre-configured with protrusions that will form recesses in the rib structures during molding. This preliminary setup allows reinforcement strips to be easily inserted through pre-formed openings without requiring complex post-processing or separate assembly operations, thus enhancing stiffness while keeping manufacturing simple
Solution Approach 2:
The cores with protrusions act as intermediaries during the molding process. They temporarily occupy space to create recesses and aligned openings in the rib structures, which then serve as accommodation channels for reinforcement strips. This intermediary mechanism enables simple integration of reinforcement elements without complex manufacturing steps
2Productivity
If accommodation structures for reinforcement strips are integrated during production, then productivity is improved, but device complexity increases
Solution Approach 1:
The formation of recesses and accommodation channels for reinforcement strips is merged with the primary injection molding process. The cores with protrusions create both the rib structures and the reinforcement strip openings simultaneously in a single molding operation, eliminating separate accommodation structure creation steps and maintaining simple tooling
Solution Approach 2:
The injection molding cores serve multiple functions: they form the rib structures, create aligned openings, and define recesses for reinforcement strip insertion all in one operation. This multi-functionality allows integration of reinforcement accommodation structures during production without increasing molding tool complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the production of load carriers with customizable reinforcement, enhancing structural integrity without complicating the molding process, ensuring secure strip placement and preventing slippage, thus improving the tray's ability to handle varied loads effectively.
Implementation Method 1
a method for injection-molding of a load carrier, particularly a tray
Data Source
AI summary
The invention relates to a load carrier, particularly a tray (1) for the transport and storage of goods, having a base (2) comprising a receiving surface (4) for the goods to be transported, and a base bottom having a structure (5) made from ribs (6, 7) crossing each other and projecting vertically from the base surface, characterized in that aligned openings (9) are made from one base side to the other in adjacent ribs (7) arranged parallel to each other, into the openings a reinforcement bar (11) can be inserted from one side of the base to the opposite side, wherein the openings (9) in the ribs (7) are formed by means of cut-outs (8) made in the vertical ribs (7) through the receiving surface (4).