Shelf frame assembly system and method
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Solution Overview
Problem
Existing plastic shelf frame assembly methods require multiple components and fixtures, leading to inefficiencies in assembly, potential glue leakage, and subsequent cleanup, while also lacking in corrosion resistance and cost-effectiveness.
Innovation Solution
The introduction of beam connectors with flexible protrusions and receiving portions that temporarily deform to secure the beams together, allowing for a more efficient and permanent assembly method using fewer components and reducing the need for additional fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hot melt glue is injected to join beams, then the joints are secured, but glue seeps out causing cleanup requirements
Solution Approach 1:
A beam connector component serves as an intermediary element between beams, providing a controlled interface for joining. The connector includes a recess that receives the beam end and a cavity that contains the adhesive, preventing glue from seeping out while maintaining joint strength.
Solution Approach 2:
The adhesive is contained within a closed cavity in the beam connector, changing its state from a free-flowing substance that seeps out to a contained substance that cures in place. This parameter change in adhesive containment eliminates glue flash while maintaining bonding effectiveness.
2Ease of manufacture
If multiple components and fixtures are used for assembly, then the shelf frame can be assembled, but the assembly process becomes complex and inefficient
Solution Approach 1:
The beam connector merges multiple functions into a single component: it provides structural support, contains the adhesive, secures the beam end, and eliminates the need for separate fixtures. This consolidation reduces assembly complexity while maintaining manufacturing efficiency.
Solution Approach 2:
The beam connector is designed to self-align and self-secure the beam end through its recess and protrusion interface. The component performs its own positioning and securing functions without requiring external fixtures or complex assembly equipment, simplifying the overall assembly process.
3Strength
If stainless steel screws are used to secure beams, then the connection is strong, but corrosion resistance and cost-effectiveness are compromised
Solution Approach 1:
The mechanical screw connection system is replaced with a chemical bonding system using adhesive contained in the beam connector cavity. This substitution eliminates the need for metal fasteners that can corrode, providing corrosion-resistant connections while maintaining adequate connection strength through properly formulated adhesive bonding.
4Object-generated harmful factors
If glue dams are used to prevent glue seepage, then glue containment is improved, but additional components and assembly steps are required
Solution Approach 1:
The glue dam function is merged into the beam connector body itself. The cavity in the beam connector serves as both the adhesive containment chamber and the structural element, eliminating the need for separate glue dam components while preventing glue seepage effectively.
Solution Approach 2:
The beam connector acts as an intermediary structure that provides a controlled environment for adhesive application. The recess and cavity work together to contain and manage the adhesive, preventing seepage without requiring additional separate components.
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
This solution enhances the assembly process by providing a corrosion-resistant, cost-effective, and efficient method for assembling shelf frames with improved interface security and reduced material waste, while simplifying the assembly process.
Implementation Method 1
Each protrusion is resilient and configured to be pressed through a respective opening in the beam to secure the beam connector to the beam
Implementation Method 2
a first beam connector (30) connected to a first end (26) of the first beam (16); a second beam connector (30) connected to a second end (28) of the first beam (16); wherein each beam connector (30) comprises: a body (32, 34); a first resilient protrusion (38) extending from a first face (32) of the body (32, 34); a first opening (44) in a second face (34) of the body (32, 34)
Data Source
Figure 1A~1B
Figure 2~3
Figure 4~5A
AI summary
A shelf frame assembly is provided. The shelf frame assembly can include a beam connector, a length beam, and an end beam. The beam connector can have a first flexible protrusion and a second flexible protrusion. The first flexible protrusion may be an interior beam indexing feature. The length beam can be configured to receive the first flexible protrusion. The end beam can be configured to receive the second flexible protrusion.