Tray Mounting Flap and Slot Locking for Tool-Free Floor Displays
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Solution Overview
Problem
Existing floor display systems for consumer products require additional hanging elements like hooks or clips to connect trays to the base, which can be cumbersome and inefficient for assembly at the point of sale.
Innovation Solution
A floor display system featuring a base portion with angled side wall slots and corresponding mounting flap portions on the trays, allowing for secure attachment without additional hanging elements, utilizing corrugated paperboard materials for ease of assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional hanging elements like hooks or clips are used to connect trays to the base, then the connection strength is improved, but the device complexity and assembly time increase
Solution Approach 1:
The slot structure integrates both the connection guide and the locking mechanism into a single integrated feature on the base. The mounting flap combines the insertion tab and the locking element into one piece. This merging eliminates the need for separate hooks or clips while maintaining secure connection strength through the slot-flap engagement geometry.
Solution Approach 2:
The mounting flap is designed to be self-latching within the slot structure. When inserted, the flap's geometry causes it to automatically lock into place without requiring additional fasteners or complex assembly steps. The corrugated paperboard material provides sufficient rigidity for the flap to maintain its locking position, making the system self-sufficient.
2Strength
If additional hanging elements like hooks or clips are used to connect trays to the base, then the connection strength is improved, but the assembly speed decreases
Solution Approach 1:
The mounting flap is pre-formed as an integral part of the tray structure during manufacturing. The slot structure is also pre-formed on the base. This preliminary preparation allows for rapid assembly at the point of sale, as no additional components need to be attached or complex alignment procedures performed. The pre-engineered geometry enables quick insertion and automatic locking.
3Reliability
If traditional mounting methods with separate hardware are used, then the connection reliability is improved, but the ease of manufacture decreases
Solution Approach 1:
The connection system is segmented into two main components: the slot structure on the base and the mounting flap on the tray. This segmentation allows each component to be manufactured independently using standard corrugated paperboard forming processes, simplifying production. The modular design enables easy manufacturing while maintaining reliable connection through the precise geometric engagement between slot and flap.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables quick and tool-free assembly of the display system at the point of sale, with the corrugated paperboard structure providing stability and ease of use, while eliminating the need for extra connecting hardware.
Implementation Method 1
The mounting flap portion may be formed of a resilient material and may be resiliently biased to engage opposing slot edges
Data Source
AI summary
A floor display system comprising a base portion including a front wall having opposing first and second vertical edges, and first and second side walls extending from the vertical edges in generally perpendicular relation to the front wall. At least one side wall slot is formed in each of the first and second side walls and connected to respective front wall slot portions formed in the front wall. At least one tray is provided including a tray body connected to at least one mounting flap portion positioned in each of the side wall slots in the first and second side walls and extending into the corresponding front wall slot portions for supporting the tray body to the base portion.