Clear Plastic Pusher Tray for Stackable Retail Displays

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Solution Overview

Problem

Existing product display systems, particularly gondola type units, are inefficient in space usage due to heavy metal parts, non-stackable designs, complex assembly, and high costs associated with injection molding tooling, which limits their adaptability and visibility of commercial packages.

Innovation Solution

A stackable display unit made from a single sheet of thermoformed clear plastic, featuring a tray with pusher arms that use score lines and vacuum forming to create a spring-biased mechanism for product visibility, allowing for easy assembly and efficient storage and shipping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If gondola type units with heavy metal parts are used, then structural strength is improved, but space efficiency and stackability deteriorate

Engineering Contradiction:

Improvestructural strengthVSAvoidspace efficiency

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The patent changes the material parameter from heavy metal to corrugated cardboard, fundamentally altering the weight-to-strength ratio. The corrugated structure provides sufficient structural strength for retail display while dramatically reducing weight and increasing space efficiency for shipping and storage.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The display unit is segmented into modular components (base, shelves, back panel) that can be independently folded and stacked. This segmentation allows the unit to be compacted for efficient shipping while maintaining structural integrity during use.

Inventive Principle:

Principle #1Segmentation

2Illumination intensity

If injection molded plastic displays are used, then product visibility is improved, but manufacturing cost and complexity increase

Engineering Contradiction:

Improveproduct visibilityVSAvoidmanufacturing cost

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

The patent employs disposable corrugated cardboard components instead of expensive injection molded plastic. The display units are designed for single-use or limited-use cycles, eliminating the need for costly tooling while maintaining adequate product visibility during their service life.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

Multiple functional elements (structural support, product pusher arms, display surfaces) are merged into single corrugated cardboard components. This consolidation eliminates the need for separate injection molded parts and complex assembly processes.

Inventive Principle:

Principle #5Merging (Combining)

3Force

If injection molded plastic pusher arms with coil springs are used, then product push functionality is improved, but device complexity and assembly difficulty increase

Engineering Contradiction:

Improveproduct push functionalityVSAvoidassembly difficulty

Core Design Contradiction:

ForceVSDevice complexity

Solution Approach 1:

The patent extracts the spring mechanism from separate coil springs and integrates it directly into the corrugated cardboard structure itself. The corrugation pattern provides the elastic rebound force, eliminating the need for separate spring components and simplifying assembly.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent uses the composite corrugated cardboard structure to simultaneously provide structural support and elastic push force. The fluted sandwich structure of corrugated cardboard inherently provides both strength and spring-like rebound when compressed.

Inventive Principle:

Principle #40Composite materials

4Stability of the object's composition

If non-stackable display units are used, then structural stability is improved, but shipping efficiency and space utilization deteriorate

Engineering Contradiction:

Improvestructural stabilityVSAvoidshipping efficiency

Core Design Contradiction:

Stability of the object's compositionVSVolume of stationary object

Solution Approach 1:

The display unit incorporates dynamic folding mechanisms that allow it to transition between an expanded stable configuration during display and a compact folded configuration for shipping. The corrugated cardboard structure maintains stability when assembled while enabling compact stacking when disassembled.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides an aesthetically pleasing, space-efficient, and cost-effective display system that keeps commercial packages visible and easily assembled, with improved resiliency and reduced material waste, enabling efficient use of space and cost-effective manufacturing.

Implementation Method 1

pusher arms that use score lines and vacuum forming to create a spring-biased mechanism

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

A stackable display unit made from a single sheet of thermoformed clear plastic

Methodology Applied

Scientific EffectVacuum forming: Vacuum

Data Source

PatentUS9192249B2Integrated product display with pusher arm

Publication Date: 2015.11.24 SCHWESTER CHARLES P

AI summary

A display including a tray having a front side and a back side and two side walls. One or more display compartments are formed within the display. A pusher arm is provided for each of the compartments. Each pusher arm has an upper side and a lower side and is connected on the lower side to the back side of the tray and slidably connected on the upper side to each of the display compartments.