Two-Piece Corrugated Shelf Assembly for Low-Cost Display Setup
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Solution Overview
Problem
Existing shelving display systems are costly and difficult to manufacture and set up, posing challenges in shipping and on-site installation.
Innovation Solution
A shelving display design featuring a back wall with U-shaped cutouts, deflectable tabs, and slots, along with side walls and shelves formed from interconnected components that can be easily assembled from a blank of corrugated material, using gluing and folding techniques to secure the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional shelving display systems are used, then structural strength and stability are maintained, but manufacturing cost and setup complexity increase significantly
Solution Approach 1:
The shelving display is divided into multiple independent components including side walls, back wall, shelves, and reinforcement elements. Each component can be manufactured separately and assembled through interlocking mechanisms, reducing manufacturing complexity and cost while maintaining structural integrity through distributed load paths
Solution Approach 2:
Multiple structural functions are combined into single elements. For example, the side walls simultaneously provide structural support, define the display boundaries, and include integrated reinforcement features. The shelves combine load-bearing capacity with easy-installation features, reducing the total number of parts needed while maintaining strength
2Ease of operation
If traditional shelving display systems are used, then structural stability is maintained, but ease of assembly and installation deteriorates
Solution Approach 1:
Connection features such as recesses, protrusions, and reinforcement elements are pre-formed during manufacturing. This preliminary preparation of joining interfaces allows for rapid on-site assembly without requiring complex tools or procedures, while the pre-engineered interlocking mechanisms ensure stable final assembly
Solution Approach 2:
The assembly process is designed to be dynamic and adaptable, allowing components to be easily connected and disconnected. The interlocking mechanisms provide stable connection during assembly but allow for disassembly if needed, combining ease of operation with structural stability
3Productivity
If complex shelving display systems are used, then structural strength is maintained, but shipping and setup difficulty increases
Solution Approach 1:
The display system is segmented into modular components that can be compactly packaged for shipping and quickly assembled on-site. Each segment is designed to be space-efficient during transport but expands into a stable structural element when assembled, improving productivity without requiring excessive simplification of the overall system
Solution Approach 2:
Components are designed with universal features that serve multiple functions. For example, side walls serve as both structural supports and mounting surfaces for shelves. This multi-functionality reduces the total number of parts needed, simplifying the system while maintaining strength and improving setup efficiency
Data Source
AI summary
A shelving display formed from a blank of material including a plurality of shelves formed from a first shelf component and a second shelf component.