Modular Divided Shelf Assembly to Reduce Corrugated Display Setup Time
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Solution Overview
Problem
Conventional corrugated card rack displays require significant labor and material costs due to the use of single sheets that 'accordion' to form multiple shelves, increasing assembly time and effort.
Innovation Solution
A divided shelf member with horizontal and vertical tabs that can be secured to a rack display base, featuring dividers to create multiple compartments, allowing for quick and efficient assembly from a knockdown configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single sheet of corrugated material is used to create multiple shelves through accordion folding, then the display structure is achieved, but assembly labor and time increase significantly
Solution Approach 1:
The patent divides the shelf structure into separate modular components - individual shelf members with pre-formed corrugated sections rather than a single continuous sheet. Each shelf member can be independently assembled and attached to the display stand, eliminating the complex accordion folding process and significantly reducing assembly time and labor requirements.
2Device complexity
If a single sheet of corrugated material is used to create multiple shelves, then the display structure is achieved, but material and labor costs increase
Solution Approach 1:
By segmenting the shelf into separate modular members, the patent simplifies the manufacturing process. Each shelf member can be produced independently using standard corrugated board forming processes, eliminating the need for complex die-cutting and folding of large single sheets. This modular approach reduces both material waste and manufacturing labor costs.
Solution Approach 2:
The shelf members are designed with self-attaching features including tabs and slots that enable easy assembly without requiring specialized tools or complex joining processes. The corrugated structure itself provides the necessary strength and alignment, allowing for rapid assembly by simply inserting and securing the modular components to the display stand.
3Device complexity
If shelves are formed by accordion folding a single sheet, then multiple shelves are created, but assembly effort increases
Solution Approach 1:
The patent segments the shelf into separate modular members that can be independently handled and assembled. Each shelf member is pre-formed with the necessary corrugated structure and can be easily attached to the display stand using simple tab-and-slot or similar mechanical joining methods, dramatically reducing the physical effort required compared to manually folding and creasing a large single sheet into an accordion configuration.
Data Source
AI summary
A divided shelf for a display rack and related methods are provided. The divided shelf transforms from a knockdown configuration to an erected configuration. The divided shelf includes divider panels to divide the shelf into more than one separate compartments. The divided shelf is affixed to a display rack base.