Stackable Rack Foot-Loop Structure for Planar Alignment
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Solution Overview
Problem
Current stackable racks face challenges in maintaining upper and lower side supports in the same plane during stacking, leading to deformation and misalignment due to issues with the sleeve and leg joints being either too tight or too loose, affecting the stability and ease of assembly.
Innovation Solution
A stackable rack design featuring side supports with trapezoid-shaped foot support means and C-shaped spring buckles to ensure planar alignment and stability, where the horizontal foot loops of one support unit fit over the upper corners of another, and C-shaped spring buckles are used to prevent disengagement between adjacent rectangular frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If sleeve joint is used for stacking the racks, then the racks can be stacked together, but the joining between sleeve and leg becomes either too tight or too loose causing misalignment and deformation
Solution Approach 1:
The support unit is divided into separate components: a rectangular frame and a foot support means with horizontal foot loops. This segmentation allows the foot loops to fit over the rectangular frames of adjacent units, creating a modular stacking system that is easy to assemble while maintaining alignment precision through the interlocking geometry of the segments.
Solution Approach 2:
The horizontal foot loops of one support unit are designed to fit over the upper corners of the rectangular frame of another support unit, creating a nested stacking configuration. This nesting arrangement ensures precise alignment and prevents misalignment during stacking operations.
2Ease of operation
If extended legs are used for stacking, then the racks can be stacked vertically, but the legs become prone to deformation and misalignment
Solution Approach 1:
The support unit is segmented into a rectangular frame structure and separate foot support means. This segmentation eliminates the need for extended legs that are prone to deformation, while the foot loops fitting over rectangular frames provides stable vertical stacking through distributed load bearing.
Solution Approach 2:
The foot support means is merged with the rectangular frame through welding to form an integrated support unit. This merging creates a stable structural configuration where the foot loops and rectangular frame work together as a unified load-bearing assembly, preventing deformation.
3Strength
If tight joining between sleeve and leg is used, then the connection is strong, but it becomes hard to align upper and lower legs during stacking
Solution Approach 1:
The connection system is segmented into separate foot loops and rectangular frame components. The foot loops are designed with sufficient clearance to fit over the rectangular frames during stacking, allowing easy alignment. Once stacked, the welding process creates a strong permanent connection, thus achieving both ease of alignment and connection strength.
Solution Approach 2:
The foot loops are pre-formed with dimensions that allow easy fitting over the rectangular frames before the final welding connection is made. This preliminary loose fit facilitates easy alignment during stacking, after which welding provides the strong permanent connection.
4Ease of operation
If loose joining between sleeve and leg is used, then alignment is easier, but misalignment occurs causing side supports to be out of plane
Solution Approach 1:
The horizontal foot loops are designed to nest over the rectangular frames of adjacent support units. This nested configuration provides geometric constraints that guide proper alignment during stacking, ensuring that upper and lower side supports remain in the same plane while still allowing easy assembly.
Solution Approach 2:
The support unit is segmented into rectangular frames and foot support means with foot loops. This segmentation creates interlocking components where the foot loops fit over the rectangular frames, providing both ease of alignment during assembly and precise planar alignment through the geometric relationship between the segmented parts.
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 design ensures that upper and lower side supports remain aligned, reducing deformation and enhancing the stability and ease of stacking, while the C-shaped spring buckles prevent disengagement, resulting in a more robust and efficient stacking system.
Implementation Method 1
a C-shaped spring buckle with one end edge turned up. When in use, an end of the C-shaped spring buckle which is not turned up grasps one side of the rectangular frame, and then the other end which is turned up snaps on one side of another rectangular frame
Data Source
AI summary
A stackable rack includes two side supports and a shelf plate between the two side supports. The side supports comprises of at least one support unit. The support unit comprises a rectangular frame and a foot support. The rectangular frame is provided with a cross bar to support the shelf plate. The foot support is bent into trapezoid with an oblate metal ring. The two ends of the trapezoid are close and bent into horizontal foot loops. The inner distance of the horizontal foot loops is a little longer than the width of the rectangular frame. The upper side of the foot support clamps the lower side of the rectangular frame and is fixed by welding. The horizontal foot loops of the support of one support unit can fit over the upper corners of the rectangular frame of another support unit, so as to stack up.