Utility Rack with Folding Cross-Members for Compact Packaging
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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, potentially leading to instability and reduced strength.
Innovation Solution
A utility rack with bolted end supports featuring folding cross members that can be easily assembled and disassembled, allowing for compact packaging and independent shelf placement, utilizing a first vertical support with permanently affixed cross members that can be connected to a second vertical support using fasteners, reducing storage space requirements while maintaining strength and rigidity.
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 support and secured with fasteners, allowing compact packaging while maintaining structural integrity when assembled. This segmentation enables the components to be stored close together without requiring the large packaging space needed for welded unitary structures.
Solution Approach 2:
The cross members are designed to be movable relative to the vertical supports through folding and connecting mechanisms. They can transition between an extended position for structural support and a collapsed position for compact storage. This dynamic capability allows the same structure to provide both strength during use and compactness during shipping and storage.
2Volume of moving object
If end supports are produced as completely disassociated individual members, then packaging size is reduced, but assembly time and complexity increase
Solution Approach 1:
The cross members are pre-attached to one vertical support using permanent affixing methods, eliminating the need for users to assemble all connections. This preliminary assembly action reduces the complexity and time required for end-user assembly while still allowing the structure to be disassembled for compact storage. Users only need to connect the cross members to the second vertical support and attach shelves.
3Ease of operation
If pin and slot connectors are used for disassociated members, then ease of assembly is improved, but stability and rigidity decrease due to play between members
Solution Approach 1:
The connection method is changed from loose-fitting pin and slot connectors to fasteners that provide a more secure, rigid connection. This parameter change in the connection mechanism maintains ease of assembly while eliminating the play and instability associated with traditional pin and slot connectors. The fasteners create tight connections that prevent tilting and swaying of the rack.
4Device complexity
If shelf supports are used as connector members for end supports, then device complexity is reduced, but adaptability of shelf placement is limited
Solution Approach 1:
The connector function is separated from the shelf support function. Dedicated connector members are used to join the vertical supports, while shelf supports are separate components that can be positioned independently. This segmentation allows shelves to be placed at multiple locations without being constrained by the structural connection points of the end supports.
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.