Modular Shelving with Reversible Interlocking for Tool-Free Assembly
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Solution Overview
Problem
Conventional modular metal shelving systems require extensive time and effort for assembly due to the need for numerous screws, and existing interlocking systems lack stability under high loads, with small hardware components being easily lost during assembly.
Innovation Solution
The shelving system employs reversible interlocking means with trapezoidal projections and openings on the uprights and shelves, allowing for tool-free assembly and disassembly, providing stable coupling without external hardware, and minimizing projecting elements for safety and compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional screw-based coupling systems are used, then stable coupling between shelves and uprights is achieved, but assembly time and complexity increase significantly due to the large number of screws required
Solution Approach 1:
The patent extracts and eliminates the screw and bolt components from the coupling system, replacing them with an integrated interlocking mechanism where protrusions on the uprights engage directly with recesses in the shelves, removing the need for separate fastening hardware
Solution Approach 2:
The coupling function is merged into the structural components themselves, with the uprights and shelves incorporating interlocking features directly in their design, combining the support and fastening functions into a single integrated system
2Volume of moving object
If small screws and bolts are used for coupling, then the overall size of components is reduced, but the risk of losing these small hardware elements during assembly increases
Solution Approach 1:
The fastening function is merged into the structural components themselves, eliminating separate small hardware elements and preventing loss by making the coupling an integral part of the shelf and upright structure
Solution Approach 2:
The patent extracts the separate fastening hardware from the system, removing screws and bolts entirely and replacing them with built-in interlocking features that cannot be lost
3Strength
If inserts with larger interlocking surfaces are used to support high weights, then load-bearing capacity increases, but the transverse extent of inserts increases causing potential safety hazards and reduced compactness
Solution Approach 1:
The interlocking features utilize asymmetric geometries where the protrusions and recesses are shaped to provide maximum contact surface area for load bearing while maintaining a compact transverse profile that minimizes safety hazards
Solution Approach 2:
The patent optimizes the interlocking surfaces by extending them in the vertical dimension rather than increasing transverse dimensions, allowing large contact areas for weight support without increasing the horizontal footprint that would create safety hazards
4Reliability
If multiple screws are required for each corner of each shelf, then stable coupling is achieved, but the complexity and cost of assembly increases
Solution Approach 1:
The patent removes the multiple screw fasteners from each corner, extracting the fastening function and replacing it with a single interlocking engagement between the upright protrusion and shelf recess
Solution Approach 2:
The coupling action is merged into a single integrated operation where the shelf is inserted into the upright and the interlocking features engage automatically, combining positioning and fastening into one step
Data Source
Figure 1~1A
Figure 2A~2B
Figure 3~4
AI summary
Shelving comprising: at least one pair of vertical uprights (2); at least one shelf (3) engaged with the two uprights (2) and defining a flat support surface (3a) arranged horizontally with respect to said vertical uprights (2); and reversible interlocking means (6) of said shelf (3) with said uprights (2); the interlocking means (6) comprising at least one series (7) of projections (8a, 8b) which extend from an inner surface (5) of a respective upright (2) and can be housed within an opening (11) formed in the shelf (3); said series (7) comprising at least a first and a second pair (7a, 7b) of projections (8a, 8b), wherein the projections (8a, 8b) of the first pair (7a) are closer than the projections (8a, 8b) of the second pair (7b).