Stackable Shelf Tray with Corner Posts to Reduce Assembly Complexity
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Solution Overview
Problem
Pallet displays often require complex assembly, are large when knocked down, and can sag under product weight, making them inefficient for shipping and display.
Innovation Solution
A tray and corner post packaging system made from three folded and glued blanks, featuring corner posts, side walls, end walls, and center supports, allowing for easy assembly and supporting multiple layers of trays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional pallet displays are made from multiple corrugated components requiring fasteners, then structural strength is improved, but assembly complexity and device complexity increase
Solution Approach 1:
The patent combines multiple separate components (bottom panel, side walls, end walls, corner posts, center supports) into a single integrated corrugated blank that is die-cut and folded into place. This merging eliminates the need for separate fasteners and multiple assembly steps while maintaining structural integrity through the interlocking folded design.
Solution Approach 2:
The single blank is die-cut into segmented sections that correspond to different structural elements (bottom, sides, ends, corners, supports). These segments are separated by fold lines that allow them to be folded into their final three-dimensional positions, creating a complex structure from a simple flat blank.
2Stability of the object's composition
If pallet displays use multiple corrugated components with fasteners, then structural stability is improved, but ease of manufacture deteriorates
Solution Approach 1:
By combining all structural elements into one pre-designed blank, the patent eliminates the need for separate manufacturing and assembly of multiple components. The blank is manufactured as a single piece with pre-scored fold lines and die-cut openings, making assembly as simple as folding and inserting tabs into slots without requiring fasteners or tools.
3Strength
If shelf trays are designed to support heavy product weight, then strength is improved, but the trays sag under load
Solution Approach 1:
The patent adds center supports at specific locations on the bottom panel to provide localized reinforcement where loads are applied. These center supports extend upward from the bottom and are positioned to prevent sagging in critical areas, allowing the tray to bear heavy loads without deforming while maintaining the overall simplicity of the single-blank design.
4Quantity of substance
If pallet displays are made large even when knocked down, then shipping capacity is improved, but storage efficiency and productivity deteriorate
Solution Approach 1:
The patent designs the knocked-down tray to nest within another tray or within itself, creating a compact stacked configuration for shipping and storage. The side walls, end walls, and corner posts are folded flat against the bottom panel, and center supports are positioned to fit within the overall footprint, maximizing storage efficiency while maintaining full shipping capacity when assembled.
Data Source
AI summary
A tray and corner post type packaging system for shipping and displaying palletized products is provided. The packaging system is made from three folded and glued blanks and includes four corner posts and a central support.