Nestable Molded Support Pad Structure for Lower Shipping Volume
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Solution Overview
Problem
Existing support pads for heavy equipment, such as HVAC condensers, are not nestable, leading to high shipping costs due to their non-stackable design, whether they are made of solid materials or molded plastic with internal ribs.
Innovation Solution
Designing molded equipment support pads with notches on the side walls that allow them to nest together, enabling efficient stacking and reduced shipping costs by aligning the notches for offset positioning, thereby allowing multiple pads to be combined and placed on a pallet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid pads or plastic molded pads with internal ribs are used to support heavy equipment, then the pads have sufficient strength and rigidity, but the pads are heavy and expensive to ship because they are not nestable
Solution Approach 1:
The pad is designed with notches in opposite side walls that enable one pad to be inserted into another, creating a nested configuration. This nesting capability allows multiple pads to be stacked vertically in a compact arrangement, significantly reducing the shipping volume and associated costs while maintaining the structural integrity needed to support heavy equipment
2Strength
If molded plastic pads with internal ribs are used to support heavy equipment, then the pads have sufficient strength, but the pads require more material and are not nestable
Solution Approach 1:
The design replaces complex internal rib structures with a simpler geometry featuring notches in the side walls. The notches enable nesting functionality without requiring intricate internal reinforcement, thus reducing overall structural complexity while maintaining the ability to support heavy equipment through the nested stacking arrangement
Solution Approach 2:
The pad structure is segmented by introducing notches in the side walls, which divide the solid structure into sections that can interlock when nested. This segmentation allows the pad to achieve both strength through the segmented reinforcement and nestability through the created openings
3Loss of energy
If pads are designed to be nestable, then shipping costs are reduced, but the pads may lack sufficient strength and rigidity
Solution Approach 1:
The notches are positioned and dimensioned to allow nesting while preserving structural strength. The notches create nesting capability by enabling interlocking of adjacent pads, yet their placement and size are controlled to maintain the rigidity of the pad walls and overall structural integrity for supporting heavy equipment
4Loss of energy
If notches are added to side walls for nesting, then pads become nestable and shipping costs decrease, but the pads require additional material processing
Solution Approach 1:
The notches are integrated into the mold design, allowing them to be formed as integral features during the molding process. This approach enables the nesting functionality to be achieved without requiring post-manufacturing operations such as cutting or drilling, thus maintaining ease of manufacture while enabling cost-effective shipping through nesting capability
Data Source
AI summary
A nesting equipment support pad is disclosed, in particular an outdoor air conditioner compressor pad. The pad comprises a parallelogram upper surface which contacts the compressor and descending side walls from each edge of the parallelogram upper surface. Two side walls include a notch to accommodate a matching notch of another identical support pad when placed in a nesting arrangement. These notched corners are at diagonally opposing corners of each pad permitting the nesting arrangements. Additional, support rib members and protrusions are located within the cavity formed by the four side walls to provide strength and rigidity. These rib members and protrusions are placed in an offset manner to permit the nesting arrangement without interference with the mating pad.