Modular Produce Crate With Interlocking Corner Connectors
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Solution Overview
Problem
Modular crate construction methods, such as those using integrally formed plastic injection techniques, are complex and expensive, lacking efficient assembly solutions that reduce complications and costs.
Innovation Solution
A modular produce crate design featuring four side panels and a base with quadrant corner connectors, where side panels enclose the base within collocated channels and engage with base connectors for secure assembly, utilizing elongate skids for simplified construction and assembly, and incorporating location tabs, deflecting clips, and buttresses for secure engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If integrally formed plastic injection techniques are used for modular crate construction, then structural integrity is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The crate is divided into separate modular components (side panels, base panel, corner connectors) that can be manufactured independently using simple injection molding, then assembled together. This segmentation avoids the need for complex integral forming while maintaining structural integrity through proper connection designs.
Solution Approach 2:
Corner connectors serve as intermediary elements that join the side panels to the base panel. These separate connector components simplify the manufacturing process by allowing independent molding of each component, while still providing the necessary structural connection that would otherwise require complex integral forming.
2Ease of operation
If traditional modular crate designs are used, then assembly simplicity is improved, but connection reliability deteriorates
Solution Approach 1:
The corner connectors are designed to nest into recesses in the side panels and base panel, creating a nested assembly structure. This nesting provides secure mechanical interlocking that ensures reliable connections while maintaining simple assembly procedures where components fit together naturally.
Solution Approach 2:
The corner connectors are pre-formed with specific geometries that match the recesses in the panels. This preliminary preparation of connection interfaces ensures that when components are assembled, they automatically align and connect reliably without requiring complex assembly operations.
3Stability of the object's composition
If corner channels engage panels therebetween, then connection stability is improved, but manufacturing complexity increases
Solution Approach 1:
The corner channel connection feature is extracted as a separate corner connector component rather than being integrated into the panels. This extraction allows the connection mechanism to be manufactured independently using simple injection molding, while still providing stable connections when the separate components are assembled together.
Data Source
AI summary
A modular produce crate has four side panels, a base panel and abase having a quadrant of upper surface corner base connectors. Each side panel defines an interior base panel channel, a pair of side panel corner connectors extending below the channel and side panel interfacing edges above the channel. Adjacent pairs of the side panel corner connectors plug into each respective corner base connector to enclose the channels around the base panel to hold the base panel and adjacent interfacing edges thereof are fastened together. As such, the base panel is held fast by the engagement of the side panel connectors within the respective base connectors thereunderneath and by the fastened interfacing edges of the side panels thereabove.