Method for making shelves
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pallet rack construction methods lack efficient and strong joining mechanisms between upright posts and horizontal beams, leading to instability and potential collapse under heavy loads.
Innovation Solution
A system involving a bar with a thin wall and a thickened portion made from folded metal, featuring fasteners such as hooks or loops, which are integrated into the structure to securely connect upright posts with horizontal beams, providing additional stability and strength while minimizing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional joining mechanisms are used between upright posts and horizontal beams, then the structure is simpler to manufacture, but the stability and strength under heavy loads deteriorates
Solution Approach 1:
The bar is divided into distinct functional segments: thin wall portions for lightweight construction and thickened portions for structural strength and fastener integration. This segmentation allows each part to optimize its function while maintaining overall structural integrity.
Solution Approach 2:
The bar features localized thickened portions at specific locations where fasteners are needed, rather than uniformly thickening the entire bar. This local quality enhancement provides strength exactly where required for joining, while keeping other portions lightweight.
2Stability of the object's composition
If thickened portions with fasteners are integrated into the bar, then the connection stability improves, but the manufacturing complexity increases
Solution Approach 1:
The fastener is merged directly into the thickened portion of the bar, forming an integrated component rather than separate parts. This combining of the fastener with the bar structure simplifies assembly while maintaining connection stability.
Solution Approach 2:
The thickened portion of the bar serves dual functions: providing structural reinforcement and housing the fastener. This self-service design eliminates the need for separate reinforcement elements and simplifies the overall manufacturing process.
3Strength
If multiple layers of folded metal are used to create thickened portions, then the strength and stability increase, but the weight increases
Solution Approach 1:
The bar maintains thin wall construction throughout most of its length to minimize weight, with localized thickened portions created by folding only at specific locations where strength is required for fastener attachment and connection.
Solution Approach 2:
Instead of increasing wall thickness uniformly in one dimension, the design uses multiple folded layers to create thickened portions, effectively adding strength in a localized manner while maintaining overall lightweight construction.
Data Source
AI summary
Beams and posts are disclosed. The beams and posts may be used for racks or shelving. The beams and posts may be formed by folding a sheet of metal. For example, the beams and posts may be non-volumous or hollow. Optionally, a portion of the wall of the beam or post is thickened, for example, by folding over the metal back and forth. Optionally, the thickened portion runs the length of the beam or post. In some embodiments, a fastener (e.g., a loop and/or hook) is formed in the thickened portion of the wall. For example, the fastener formed by punching out of the wall. Optionally, the fasteners are used to connect the posts to the beams.