Stackable Carrier Assembly with Vertical Nesting Tracks
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Solution Overview
Problem
Existing carrier systems cannot be efficiently stacked due to their design, leading to excessive storage space requirements in manufacturing facilities, which results in increased costs for additional storage space.
Innovation Solution
A stackable carrier assembly system that includes a base member with a load surface and a transport surface, where multiple carrier trolleys are coupled to the transport surface and track sections are coupled to the load surface, allowing for vertical stacking of carrier assemblies using a conveyor system and lift mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If carriers are stored in idle rows of conveyor tracks or on the floor, then carriers can be stored for future use, but large floor space is required which limits available space for manufacturing operations
Solution Approach 1:
The patent applies vertical stacking to store carriers in the vertical dimension rather than spreading them horizontally across the floor. Multiple carriers are stacked one on top of another using track sections that extend vertically from the load surface, transforming a 2D storage problem into a 3D solution and dramatically reducing floor space requirements.
Solution Approach 2:
The patent implements a nesting arrangement where carriers are stacked vertically with each carrier containing track sections that receive and support the carriers above it. The track sections act as nested structures, with each level of carriers fitting into the vertical arrangement of track sections from the level below, maximizing space utilization.
2Reliability
If carriers are designed with multiple load bars and trolley wheels for conveyor operation, then carriers can be reliably transported, but carriers cannot be stacked on top of one another like skids
Solution Approach 1:
The patent makes the track sections serve dual functions: they guide and support carriers during horizontal conveyor operation, and they provide vertical stacking support when carriers need to be stored. The same track sections that enable reliable conveyor transport also enable stacking capability, eliminating the need for separate stacking structures and providing multi-functionality.
Solution Approach 2:
The patent merges the conveyor function and stacking function into a single integrated system. The track sections are designed to perform both conveyor guidance and vertical support functions, combining what were previously separate requirements into one unified structure that achieves both reliable transport and stacking capability.
Data Source
AI summary
A stackable carrier assembly, carrier stacking system, and method of storing carrier assemblies is disclosed. The carrier assembly includes a base member presenting a load surface and opposite facing transfer surface. A plurality of carrier trolleys extend transversely from the load surface to engage conveyor tracks. A plurality of track sections are coupled to the load surface for receiving the carrier trolleys of another carrier assembly. The track sections are vertically aligned with the carrier trolleys. In a power and free or friction drive conveyor system, a lift device and telescoping arm can lift and stack the carrier assemblies so that track sections of one carrier assembly receive the carrier trolleys of another carrier assembly. In an overhead conveyor system, one carrier assembly can hang from the track sections of another carrier assembly.