Modular Greeting Card Rack With Tab-Slot Shelf Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional corrugated card rack displays require significant labor and material for assembly due to the need for multiple shelves made from a single sheet of corrugated material, which 'accordions' to form multiple levels, increasing manufacturing and assembly time and costs.
Innovation Solution
A modular rack display design featuring a base with horizontal and vertical slots and shelf members with corresponding tabs, allowing for easy assembly by inserting tabs into slots, reducing the complexity and time required to transform the display from a knockdown to an erected configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional single-sheet corrugated shelves are used to form multiple levels, then structural integrity is maintained, but assembly labor and time increase significantly
Solution Approach 1:
The shelf is divided into multiple independent components: a base component with slot openings and separate shelf components with tabs. This segmentation allows each component to be manufactured independently and assembled quickly by inserting tabs into slots, eliminating the complex accordion folding process while maintaining structural integrity through the tab-slot connection mechanism.
2Productivity
If conventional accordion-style shelves are used, then structural integrity is maintained, but manufacturing time and costs increase
Solution Approach 1:
The shelf is segmented into a base component and separate shelf components that can be manufactured independently using standard die-cutting processes. This allows for parallel manufacturing and reduces production time compared to the sequential accordion folding process, while the tab-slot connection ensures structural integrity during assembly.
3Loss of time
If tabs and slots are used for modular assembly, then assembly time is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The slot and tab design uses standardized, repeatable geometric features that can be manufactured with conventional die-cutting equipment. The universal nature of these connection features allows for consistent manufacturing tolerances across multiple components, reducing the need for high-precision custom fitting while enabling quick assembly through simple insertion motions.
Data Source
AI summary
A rack display having a base having a front panel with a plurality of horizontal and vertical slots included thereon; left and right side panels extending from sides of the front panel; a back panel extending between the left and right side panels; and one or more shelf members including horizontal and vertical tabs. The shelf members are secured to the base by inserting the vertical and horizontal tabs within the vertical and horizontal slots respectively. The rack display is erected from a knockdown configuration by securing the shelf members to the front panel of the base via insertion of the horizontal and vertical tabs within the horizontal and vertical slots respectively.