Stackable Module Tray Structure for Stable Load-Bearing Interlock
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Solution Overview
Problem
Stackable module trays face issues with stability and durability due to unstable stacking lugs and low load-bearing capacity, leading to potential deformation or failure under weight, especially when multiple trays are stacked.
Innovation Solution
The module tray features side parts connected to the tray body in a buckling-proof manner via vertical fold lines, forming a stable receptacle with a triangular cross-section, and reinforced with adhesive flaps and additional fold lines for enhanced stability and load distribution, allowing for interlocking and superimposed supporting elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If stacking lugs are machined from the side walls to enable stacking, then stacking functionality is achieved, but the stacking lugs become unstable and insufficiently durable under load
Solution Approach 1:
The side wall is segmented into multiple layers (outer layer, inner layer, and intermediate layer) with the stacking lug formed by the inner layer. This segmentation allows the stacking lug to be structurally separated from the outer wall surface, providing independent structural support and improved stability while maintaining stacking functionality.
Solution Approach 2:
The side wall is constructed as a composite structure with multiple layers of different materials or densities. The inner layer forms the stacking lug while the outer layer provides surface integrity. This composite construction ensures that the stacking lug maintains both its stacking function and structural stability under load.
2Ease of manufacture
If the tray body is constructed with multiple layers and plug-in connections to reduce material usage, then manufacturing cost is reduced, but the tray exhibits low stability and undergoes deformation under load
Solution Approach 1:
The intermediate layer is selectively positioned at critical structural locations where load transmission occurs, such as at the plug-in connection points and beneath the stacking lugs. This local reinforcement strategy maintains the overall lightweight multi-layer construction while providing targeted strength enhancement where needed to prevent deformation under load.
Solution Approach 2:
The intermediate layer is pre-positioned within the multi-layer structure during manufacturing to provide preliminary structural support. This preliminary reinforcement is built into the tray body before the tray enters service, ensuring that the plug-in connections and stacking lugs have adequate structural backing from the outset to prevent deformation under load.
3Device complexity
If simple tab-based receptacles are used in the side walls, then the structure remains simple and manufacturing is easy, but the receptacles provide insufficient stability and the module tray can fail under load
Solution Approach 1:
The receptacle structure is segmented into multiple functional components: the tab element for insertion, the intermediate layer for structural reinforcement, and the outer layer for surface integration. This segmentation transforms the simple tab into a multi-component system that maintains ease of manufacture while providing the structural stability needed to prevent tray failure under load.
Data Source
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AI summary
The tray (1) has supporting elements (45.1, 45.2) connected with a supporting element of another module tray, and with a tray body (3) made of cardboard box material. The tray body comprises an access opening on a front wall (11) and retainers (44.1, 44.2) on side panels (6.1, 6.2). Lateral adhesive straps (25.1, 25.2) are hinged at sides of side walls by vertical fold lines (27.1, 27.2, 28.1, 28.2), where the sides are pointed towards an access opening. The straps are folded along one of the vertical folding lines.