Tray Cover and Insert Mechanical Interlock Assembly
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Solution Overview
Problem
Existing tray designs face challenges in ease of assembly and durability, with a need for secure locking of side walls and a means to hide folded webbings and tabs without permanent deformation, and require adhesive or tape for securing components.
Innovation Solution
The design incorporates a tray insert with wall anchoring protrusions and slots, and a cover with floor securing protrusions and slots, allowing for secure assembly without adhesives, and features like flexing slits and cut-outs to enhance durability and aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive or tape is used to secure components, then reliability of component attachment is improved, but ease of manufacture deteriorates due to additional bonding steps
Solution Approach 1:
The patent replaces adhesive bonding with a mechanical interlocking system using protrusions and slots. The cover protrusion inserts into the tray insert slot, creating a secure mechanical connection that eliminates the need for adhesives or tapes, thereby simplifying the assembly process while maintaining reliable component attachment.
Solution Approach 2:
The patent changes the attachment mechanism from chemical bonding (adhesive) to mechanical engagement (protrusion-slot interface). This parameter change in the attachment method allows for easier assembly without compromising the reliability of component attachment, as the mechanical interlock provides secure fastening through geometric constraints rather than chemical bonds.
2Strength
If side walls are made rigid for structural stability, then strength is improved, but ease of operation deteriorates due to difficulty in folding and assembly
Solution Approach 1:
The patent segments the side wall into multiple functional zones: a rigid upper portion for structural stability and strength, and a flexible lower portion containing fold lines for ease of folding and assembly. This segmentation allows the side wall to exhibit both rigidity when needed for support and flexibility when needed for assembly operations.
Solution Approach 2:
The patent introduces dynamic characteristics to the side wall through fold lines that allow the structure to transition between flat and three-dimensional states during assembly. The side wall can be flexed along predetermined lines to facilitate folding operations, then locks into a rigid configuration when assembled, providing both ease of operation and structural stability.
3Shape
If folded webbings and tabs are hidden using cut-out regions, then appearance is improved, but device complexity increases due to additional design features
Solution Approach 1:
The patent extracts the folded webbings and tabs from the visible surface by providing cut-out regions that accommodate these elements. The webbings and tabs are taken out from the front view by being positioned within the cut-out areas, hiding them from sight while maintaining the structural integrity and functionality of the tray assembly.
Solution Approach 2:
The patent uses the cut-out region to nest the folded webbing and tab structures within the cover structure. The webbing and tabs are nested within the spatial envelope defined by the cut-out, allowing them to be concealed while remaining part of the overall assembly. This nesting approach improves appearance without requiring separate hiding components.
4Adaptability or versatility
If multiple separate components are used for tray construction, then adaptability is improved, but device complexity increases due to more parts to assemble
Solution Approach 1:
The patent merges the floor and cover into an integrated floor cover assembly, reducing the number of separate components. The floor cover portion is attached to the cover, creating a combined element that simplifies assembly while maintaining the adaptability benefits of having separate tray insert and cover components.
Solution Approach 2:
The tray insert is designed with universal features including slots that can accommodate various protrusion types and floor cover configurations. This multi-functionality allows the same basic tray insert design to work with different cover and floor cover variations, maintaining adaptability while reducing overall system complexity through standardized interfaces.
Data Source
AI summary
The present teachings are direct at tray, components in a tray, methods for assembling trays, and articles, such as boxes that include a tray. The covers and/or tray inserts include one or more features that result in one or more of the following benefits: improved performance during or after assembly of a tray, improved ease of assembling a tray, or improved appearance of a tray, or any combination thereof. The features can be used alone. However, a number of the features when combined, result in particularly robust assembly processes.