Box Height Reduction via Tear Line Segmentation and Folding
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Solution Overview
Problem
Existing methods for reducing the height of boxes made of foldable material to match the height of their contents while closing them are inefficient, requiring cutting tools that wear out quickly and generate waste, and often necessitate additional materials or complex machinery.
Innovation Solution
A method and machine that break connections between the side walls of a box at the top, fold the high sections towards the center, and secure them in a horizontal plane using clamps and adhesive means, without using cutting tools or additional materials, to adjust the box height to match the contents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If cutting tools are used to reduce box height, then box height can be reduced to match contents, but cutting tools wear out quickly and generate waste
Solution Approach 1:
The box side walls are segmented into two parts: a lower fixed portion and an upper movable portion connected by a tear line. The tear line allows the upper portion to be separated cleanly without cutting tools, eliminating tool wear and reducing waste material generation while achieving the desired height reduction.
Solution Approach 2:
The tear line is pre-formed during box manufacturing, enabling easy separation of the upper side wall portion without requiring cutting tools during the height reduction process. This preliminary preparation eliminates the need for cutting operations and their associated problems.
2Reliability
If additional materials are used to close the box after height reduction, then the box can be securely closed, but costs increase
Solution Approach 1:
The box's own material (the upper portion of the side walls) is used to close the box after height reduction. The detached upper portions are folded inward to form a closure flap, eliminating the need for additional closing materials and reducing costs while maintaining reliable closure.
Solution Approach 2:
The upper portion of the side walls serves multiple functions: it provides the height reduction feature and simultaneously acts as the closure mechanism. This multi-functionality eliminates the need for separate closing materials.
3Manufacturing precision
If complex machinery is used to reduce box height, then height can be precisely adjusted, but device complexity increases
Solution Approach 1:
The tear line is pre-formed at the exact location where height reduction is needed, allowing precise height adjustment without complex machinery. The pre-positioned tear line ensures accurate separation at the desired height while keeping the equipment simple.
Solution Approach 2:
The complex cutting and measurement functions are extracted from the box-forming process and replaced by the pre-formed tear line feature. This eliminates the need for complex height-adjustment machinery while maintaining precision through the predetermined tear line position.
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
This method allows for efficient, cost-effective reduction of box height and closure without waste generation, using only the box material, thus reducing shipping costs and simplifying the process.
Implementation Method 1
at least four adhesive means positioned at the base of said box, each said adhesive means being capable of joining said high sections, folded towards the inside of said box, in a horizontal plane to the base of the box
Data Source
AI summary
Method and machine for reducing the height of a box without removing a section of the material of the box and without the use of any cutting tool whatsoever, but by folding high sections of side walls towards the centre of the box. The method includes: breaking the connections between the side walls along the upper section of the vertical ridges of the box, from the height of the vertical walls of the box to the level of the top of the stack of objects previously positioned in the box, by exerting a force, directed towards the exterior of the box, on the high section of at least two of the side walls; simultaneously folding towards the exterior the high sections on which force is exerted; then folding all the high sections towards the interior of the box, in order to bring the side walls into a substantially horizontal plane.