Storage Box Tray Fastener Slots for Weight Capacity
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Solution Overview
Problem
Existing storage boxes, such as bankers boxes, have limited weight capacity due to the passive engagement between the support flaps and the sidewall enclosure, which can be easily overcome by minimal force.
Innovation Solution
A storage box design featuring a sidewall enclosure with fasteners extending from the bottom edge, securely coupling a tray to the enclosure through fastener slots, enhancing the weight capacity by providing a secure engagement mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If passive engagement between support flaps and sidewall enclosure is used, then device complexity is reduced, but weight capacity is limited
Solution Approach 1:
The engagement mechanism is segmented into multiple fasteners distributed at different locations along the tray's engagement edge. Each fastener operates independently, and collectively they provide enhanced securing force while maintaining relative simplicity in each individual component.
Solution Approach 2:
The fasteners extend in a direction perpendicular to the engagement surface, creating a third dimension of engagement. This vertical extension allows the fasteners to penetrate or engage with the sidewall enclosure from the tray, providing mechanical interlocking that significantly increases weight capacity without complicating the overall engagement mechanism.
2Ease of manufacture
If passive engagement between support flaps and sidewall enclosure is used, then ease of manufacture is improved, but reliability is reduced
Solution Approach 1:
The fasteners are designed to be self-aligning and self-securing. The tray's engagement edge naturally guides the fasteners into proper alignment with the sidewall enclosure features, and once engaged, the fasteners automatically secure the tray without requiring additional adjustment or complex assembly steps.
Solution Approach 2:
The fasteners are pre-positioned on the tray during manufacturing, aligned with engagement features on the sidewall enclosure. This preliminary positioning ensures that during final assembly, the fasteners automatically engage with the correct features without requiring precise manual alignment, thereby maintaining ease of manufacture while improving engagement reliability.
Data Source
AI summary
A tray blank for a storage box includes a planar center panel defining a first side edge, a second side edge opposite the first side edge, a first end edge, and a second end edge opposite the first end edge, a first fastener slot formed through the center panel at the first side edge and a second fastener slot formed through the center panel at the second side edge, the first fastener slot laterally aligned with the second fastener slot; a first side panel formed monolithically with the center panel and hingedly connected to the first side edge, the first side panel coplanar with the center panel; and a second side panel formed monolithically with the center panel and hingedly connected to the second side edge, the second side panel coplanar with the center panel and the first side panel.