Modular Crate Panels With Interlocking Connectors for Custom Sizing

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Solution Overview

Problem

Traditional crates are heavy, expensive, labor-intensive, and often single-use items that require custom fabrication or standard sizes, limiting their versatility and sustainability.

Innovation Solution

Modular crate components comprising panels, connectors, and fasteners that allow for quick assembly of customizable crates using lightweight, reusable plastic panels with interlocking teeth and connectors that require minimal tools and expertise.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional wooden crates are custom made to accommodate items, then the crate size can be precisely fitted, but the manufacturing cost and labor intensity increase significantly

Engineering Contradiction:

Improvecrate size fitVSAvoidmanufacturing cost and labor intensity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The crate is divided into modular components including panels with standardized edges, connectors, and fasteners. These segments can be assembled in different configurations to create crates of various sizes, eliminating the need for custom fabrication while maintaining precise fit through standardized interlocking mechanisms.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The modular components are designed with universal interfaces that allow the same panels and connectors to be used across different crate sizes and configurations. The standardized edges with teeth and slots enable the same component set to serve multiple functions in constructing different crate types.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If traditional crates are made to be reusable, then sustainability improves, but they remain heavy and expensive to manufacture

Engineering Contradiction:

ImprovereusabilityVSAvoidcrate weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The crate components utilize composite construction combining plastic panels with metal connectors and fasteners. This composite approach provides the necessary structural strength for reusability while reducing overall weight compared to traditional all-wood construction.

Inventive Principle:

Principle #40Composite materials

3Productivity

If modular panels use interlocking teeth and connectors, then assembly speed increases, but the connector design becomes more complex

Engineering Contradiction:

Improveassembly speedVSAvoidconnector design complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The connector integrates multiple functions into a single component: it receives the post from one panel, engages with slots on adjacent panels, and provides attachment points for fasteners. This merging of functions into one element simplifies the overall design while enabling rapid assembly through intuitive interlocking actions.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20260084860A1Modular crate components and systems

Publication Date: 2026.03.26 CRATIVE LLC

AI summary

Modular crate components and systems can include panels, connectors, and fasteners useable to create crates of different sizes. The panels can include a plurality of teeth along each of the edges of the panel that can interlock or intermesh with a plurality of teeth of an adjacent panel. At least some of the teeth can include posts that are configured to engage with the connectors to facilitate coupling the panels together. The connectors can include an arrangement of slots that are positioned and configured to engage with the posts included on at least some of the teeth. Each connector can also be configured with an opening configured to receive a fastener therethrough.