Self-Mounting Collapsible Tray Corner Pillar Reinforcement
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Solution Overview
Problem
Self-mounting and collapsible trays that are glued and folded in origin face challenges in material distribution and compressive strength, leading to difficulties in folding and stability during use, especially when trying to reinforce the end wall and prevent detachment under outward forces.
Innovation Solution
A self-mounting and collapsible tray design featuring corner pillars with four segments, where the last segment extends along the end wall instead of being hidden inside, allowing for increased reinforcement and easier folding, along with transversal flaps for enhanced stability and resistance to outward forces, and optional features like holes and notches for locking mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the last segment of the corner pillar is housed inside the corner pillar to reduce horizontal length, then the tray becomes more compact, but the compressive strength of the corner is reduced and material distribution is optimized poorly
Solution Approach 1:
The last segment is repositioned from an internal horizontal arrangement to an external arrangement extending along the end wall, utilizing the longitudinal dimension of the end wall rather than consuming horizontal corner space. This dimensional reconfiguration allows the segment to contribute to compressive strength along the end wall while maintaining compact folded dimensions.
Solution Approach 2:
The last segment is strategically positioned to extend along the end wall where it can provide localized reinforcement and optimize material distribution in the critical end wall region, rather than being hidden inside the corner pillar where it would not contribute effectively to structural strength.
2Strength
If the last segment is extended along the end wall for reinforcement, then the compressive strength and material distribution are optimized, but the folding difficulty increases due to material accumulation in the corner
Solution Approach 1:
The corner pillar is divided into multiple segments (first, second, third, and last segments) with distinct functions. The last segment is separated from the corner housing structure and repositioned to extend along the end wall, allowing independent optimization of its length and position without interfering with the folding mechanics of the corner joint.
Solution Approach 2:
The last segment is extracted from the traditional corner housing configuration and repositioned to extend along the end wall. This extraction removes the material accumulation problem from the corner area, enabling easier folding while maintaining the reinforcement function along the end wall.
3Device complexity
If traditional corner pillars are used with hidden last segments, then the folding mechanism is simple, but the tray lacks sufficient reinforcement and stability under outward forces
Solution Approach 1:
The corner pillar segments are designed with controlled mobility through fold lines, allowing dynamic transformation between folded and erected states. The last segment extending along the end wall provides dynamic reinforcement that activates during erection, enhancing stability under outward forces while maintaining folding simplicity.
Solution Approach 2:
The corner pillar assembly functions as a composite structure with multiple segments (first, second, third, and last segments) made from the same material but configured differently to perform complementary functions: corner joining, folding articulation, and end wall reinforcement, achieving enhanced overall performance.
Data Source
AI summary
The self-mounting and collapsible tray has a base (1), two side walls (2) and two end walls (3), as well as, in correspondence with each corner, a corner pillar which comprises at least four segments (41-44) separated by fold lines (4a-4c).The last segment (44) is affixed to the end wall so that at least one part of the last segment extends from one of the intermediate segments (43) and toward the center of the end wall, distancing itself from the corresponding corner of the tray. In addition, the tray comprises, in correspondence with each end wall (3), a transversal flap (5) constituted by at least one part of a prolongation of the end of the end wall which corresponds to the upper part of the end wall of the tray in the erect position, said transversal flap (5) having two ends (51), each folded over and affixed to an outside face of the corresponding side wall (2).