Utility Rack with Folding Cross-Members to Reduce Packaging Size
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Solution Overview
Problem
Existing shelving systems face challenges with large packaging sizes due to rigid end supports, which increase storage and shipping costs, and require time-consuming assembly with unassembled systems, often resulting in instability and reduced strength.
Innovation Solution
A bolted utility rack design featuring folding cross members that can be easily assembled and disassembled, allowing for compact packaging and storage while maintaining strength and rigidity, with cross members mounted on vertical supports that can be connected using fasteners for secure alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If end supports are fabricated as unitary welded structures, then strength and rigidity are improved, but packaging size and storage space requirements increase
Solution Approach 1:
The end support is divided into separate components: vertical supports and cross members that can be disconnected. The cross members can be folded against the vertical supports and secured with fasteners, allowing compact packaging while maintaining structural integrity when assembled.
Solution Approach 2:
The cross members are designed to be movable relative to the vertical supports through folding and fastening mechanisms. This dynamic configuration allows the structure to transition between a compact stored state and a rigid assembled state, resolving the contradiction between packaging size and strength.
2Strength
If end supports are fabricated as unitary welded structures, then strength and rigidity are improved, but ease of storage and transportation deteriorates
Solution Approach 1:
By segmenting the end support into detachable vertical supports and cross members, the system becomes easier to store and transport. The cross members fold against the vertical supports and are secured with fasteners, creating a compact configuration that is simple to handle while maintaining strength when assembled.
Solution Approach 2:
The physical configuration of the end support changes between a compact folded state for storage/transport and an extended rigid state for use. The fastening mechanism enables this parameter change, allowing the same structure to optimize for different operational requirements.
3Volume of moving object
If unassembled end supports with pin and slot connectors are used, then packaging size is reduced, but stability and rigidity deteriorate due to play between members
Solution Approach 1:
The fastening mechanism is extracted as a separate functional element that eliminates play between the pin and slot connections. By adding this fastening component, the system achieves both compact packaging and stable assembly, resolving the contradiction between reduced packaging size and maintained stability.
4Device complexity
If unassembled end supports require purchaser assembly, then manufacturing complexity is reduced, but assembly time and effort increase
Solution Approach 1:
The cross members are pre-attached to one vertical support, and the fastening mechanism is pre-configured. This preliminary action reduces the assembly process to simple fastening operations rather than complete assembly from separate parts, significantly reducing assembly time while maintaining manufacturing efficiency.
Data Source
AI summary
A utility rack includes a pair of end supports for supporting one or more shelves there between. Each end support includes a first vertical support having one or more cross members mounted thereto and a second vertical support. The cross members may be mounted to one or more cross member mounts of the first vertical support and are configured to be movable relative to the first vertical support between a stored position in which they are disconnected from the second vertical support and are collapsed inwardly towards the first vertical support for storage or transport and an extended position in which free ends of the cross members may be attached to the second vertical support using fasteners.