Stackable Crate Design Using Triangular Blocks and Wooden Dowels
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Solution Overview
Problem
Existing crate solutions face challenges such as sensitivity to moisture, high manufacturing costs due to precision cutting requirements, structural weaknesses leading to breakage during stacking and transport, and difficulties in recycling due to metal staples, which affect their recyclability and alignment.
Innovation Solution
A disassemblable and stackable crate design featuring four triangular blocks with elongated mounting holes for longitudinal and end members, bayonet-type fasteners, and beveled corners that allow for secure assembly and stacking without staples, distributing weight directly through the blocks for enhanced stability and ease of assembly/disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal staples are used to fasten the crate parts, then the assembly strength is improved, but the recyclability deteriorates and rust occurs
Solution Approach 1:
The patent removes metal staples entirely from the crate assembly system and replaces them with wooden dowels and wooden fastening elements. This extraction of the harmful metal component eliminates rust and recyclability problems while maintaining assembly strength through alternative wooden fastening mechanisms.
Solution Approach 2:
The patent changes the material parameter of the fastening elements from metal to wood, specifically using wooden dowels and wooden fasteners that match the wooden crate material. This parameter change eliminates the harmful effects of metal while preserving the structural integrity through properly designed wooden joining mechanisms.
2Manufacturing precision
If precision cutting systems are used to manufacture crate parts, then the manufacturing precision is improved, but the manufacturing cost increases
Solution Approach 1:
The patent divides the crate into modular components (sides, ends, blocks, dowels) that can be manufactured using simpler, less precise cutting methods. The segmentation allows each part to be produced independently with standard woodworking equipment, reducing the need for expensive precision laser cutting systems while maintaining adequate fit-through the use of standardized joint designs.
3Device complexity
If blocks with small contact surfaces are used, then the crate structure is simplified, but the stacking capability deteriorates
Solution Approach 1:
The patent enhances the stacking capability by adding vertical dimension features to the blocks, specifically recesses and protrusions that engage with corresponding features on adjacent crates. This dimensional addition allows for stable vertical stacking without increasing the horizontal contact surface area, maintaining structural simplicity while improving stacking stability through three-dimensional geometric engagement.
4Device complexity
If hooks with weak structure are used for fastening, then the assembly is simplified, but the reliability deteriorates under lateral movement
Solution Approach 1:
The patent incorporates recesses and protrusions in the block design that provide preliminary geometric constraint and cushioning against lateral movements. These features are designed in advance to absorb and distribute lateral forces, preventing the fastening elements from experiencing excessive stress that would lead to breakage, thereby maintaining reliability without complicating the overall structure.
Data Source
AI summary
The invention relates to a disassemblable and stackable crate comprising two longitudinal members (1, 1') opposite one another; two end members (2, 2') opposite one another; a bottom (3) and four blocks (4), each of which comprises at least one inner face (42) and two outer faces (43); and wherein the inner face (42) of each block (4) in turn comprises at least two elongated mounting holes (4a), where each of the elongated mounting holes (4a) dimensionally corresponds with tabs (1a, 2a) of the sides (1, 1', 2, 2'); and wherein said tabs (1a, 2a) of each longitudinal member (1, 1') and each end member (2, 2') are coupled in the elongated mounting holes (4a) of the blocks (4) without needing to bend them, such that each block (4) is located outside the perimeter defined by the sides (1, 1', 2, 2').