Modular Ladder With Interlocking Steps And Uprights
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Solution Overview
Problem
Existing ladder assembly methods require irreversible fixing operations like welding, increasing manufacturing, maintenance, and shipping costs, as ladders are typically assembled and shipped in a fixed state.
Innovation Solution
A modular ladder design with disassembled components that can be easily assembled using common tools like hammers and screwdrivers, featuring interlocking mechanisms with tongues and slits, allowing for disassembly and reassembly without specialized tools, enabling cost-effective production and transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If irreversible fixing operations like welding are used to assemble ladders, then the structural strength and stability are improved, but the manufacturing cost, maintenance cost, and shipping cost increase
Solution Approach 1:
The ladder is divided into separate modular components (uprights and steps) that can be assembled and disassembled. Each component is independently manufactured, allowing for cost-effective production and reduced shipping costs while maintaining structural integrity through the interlocking mechanism.
Solution Approach 2:
An intermediary interlocking mechanism is introduced between the uprights and steps. This mechanism features receiving portions on the uprights and engaging portions on the steps, creating a reversible connection that maintains structural strength without requiring welding or irreversible fixing operations.
2Stability of the object's composition
If ladders are assembled and shipped in a fixed state, then the structural stability is maintained, but the transportation cost and storage space increase
Solution Approach 1:
The ladder is segmented into separate components (uprights and steps) that can be shipped disassembled, reducing transportation volume and cost. The components are designed with interlocking features that ensure stable reassembly at the destination.
Solution Approach 2:
The ladder transitions from a static assembled state to a dynamic configurable state. The reversible interlocking mechanism allows the ladder to be easily assembled and disassembled, providing flexibility in transportation and storage while maintaining structural stability when assembled for use.
3Quantity of substance
If modular components are used that can be disassembled, then the shipping cost is reduced, but the assembly complexity increases
Solution Approach 1:
The interlocking mechanism serves as a simple intermediary that facilitates easy assembly and disassembly. The receiving portions and engaging portions are designed to work together in a straightforward manner, reducing assembly complexity despite the modular design.
Solution Approach 2:
The interlocking mechanism is designed to be self-aligning and self-securing. The engaging portions automatically fit into the receiving portions without requiring complex alignment procedures or specialized tools, allowing end users to assemble the ladder themselves.
4Ease of operation
If reversible interlocking mechanisms are used, then the ease of assembly is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The interlocking mechanism with receiving and engaging portions is designed as a robust intermediary that provides tolerance for manufacturing variations. The geometry of the interlocking features ensures proper alignment and connection even with moderate manufacturing precision, maintaining ease of assembly.
Data Source
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AI summary
A ladder (1) comprising two vertical uprights (2) and a plurality of horizontal steps (3) supported by the uprights (2). Each upright (2) is a vertical section bar which branches off from at least one end of the two side walls (P2) and is parallel to the outer wall (P1). Each step (3) is a C-shaped section bar and has a horizontal upper wall (P5) and two vertical side walls (P6) which branch off from opposite ends of the upper wall (P5). The outer wall (P1) of each upright (2) is provided with a plurality of outer through-holes (4) which enable the insertion of the steps (3) therein. The inner wall (P3) of each upright (2) is provided with a plurality of inner through-holes (5) which enable the insertion of the steps (3) therein. The side walls (P6) of each step (3) are provided with slits (6) which enable the interlocking of the steps (3) with the inner walls of the uprights (2).