Adjustable Container With Foldable Gusset Panels

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Solution Overview

Problem

Businesses face increased shipping costs due to dimensional weight pricing, as they often use standard container sizes that do not account for the actual space occupied by products, leading to higher costs when dimensional weight exceeds actual weight.

Innovation Solution

An adjustable corrugated container with foldable gusset panels and an adjustable sleeve that allows the container to expand or contract, accommodating various product sizes and reducing shipping costs by optimizing package density.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If standard container sizes are used for all shipments, then manufacturing and inventory management are simplified, but shipping costs increase due to dimensional weight pricing

Engineering Contradiction:

Improvecontainer standardizationVSAvoidshipping cost

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The container employs foldable gusset panels that allow it to dynamically change its dimensions. The gusset panels can be folded to expand the container for large products or collapsed to shrink it for small products, enabling the same container to adapt to different product sizes and minimize dimensional weight charges.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The container's physical parameters (length, width, height) are made changeable through the foldable gusset mechanism. By adjusting the fold state of the gusset panels, the container can transform between multiple size configurations, allowing businesses to optimize package density and reduce shipping costs based on actual product dimensions.

Inventive Principle:

Principle #35Parameter changes

2Loss of energy

If adjustable gusset panels are added to allow container size variation, then shipping cost optimization is achieved, but device complexity increases

Engineering Contradiction:

Improveshipping costVSAvoidcontainer structure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The container is segmented into distinct functional components: base walls, end walls, and foldable gusset panels. This segmentation allows each component to perform its specific function independently, with the gusset panels providing the adjustment mechanism while the base and end walls maintain structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The gusset panels utilize flexible folding mechanisms that allow the container walls to bend and adjust. These flexible elements enable the container to transition between expanded and contracted states without requiring complex mechanical systems, motors, or fasteners.

Inventive Principle:

Principle #30Flexible shells and thin films

3Adaptability or versatility

If the container is designed to expand and contract, then adaptability to various product sizes is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvecontainer size adjustmentVSAvoidfold line alignment

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The fold lines and cut lines are pre-marked and pre-positioned on the container blank during manufacturing. This preliminary action ensures that when the container is assembled, the gusset panels align correctly with the base and end walls, enabling proper folding and expansion without requiring complex adjustment mechanisms.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The container design incorporates asymmetric fold and cut patterns that naturally guide the gusset panels into their correct positions. The asymmetric positioning of fold lines relative to the base walls and end walls ensures proper alignment during assembly and operation.

Inventive Principle:

Principle #4Asymmetry

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

The adjustable container provides significant savings in shipping costs by allowing businesses to use the appropriate container size based on product size, reducing dimensional weight and enhancing flexibility in packaging and display.

Implementation Method 1

The adjustable container includes first gusset panels in the respective opposite side walls joined along fold lines extending perpendicular to the bottom wall

Methodology Applied

Scientific EffectFolding: Folding

Data Source

PatentUS9546014B2Adjustable container

Publication Date: 2017.01.17 INT PAPER CO

AI summary

An adjustable container capable of being converted from an expanded position to a contracted position and comprises a bottom wall, opposite sidewalls, and opposite end walls foldably joined to one another to form an interior space for containing articles. Each of the opposite sidewalls includes a pair of first gusset panels each of which including two identical coextensive panels having the same height as the side walls and is configured to be perpendicular to the respective sidewalls and the bottom wall. The bottom wall includes a second gusset panels that is defined by two identical coextensive panels and having the same height as the side walls and is folded upwardly out of the plane of the bottom wall and perpendicular thereto when the adjustable container is in the contracted position. The adjustable container also includes an adjustable sleeve that is used to securely cover the container during shipping and transportation.