Packaging Box Internal Wall Segmentation for Leaflet Extraction
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Solution Overview
Problem
Existing box designs that house illustrative leaflets make it difficult to extract the leaflet and insert products, such as bottles or blister strips, due to the internal wall and leaflet's free edge causing obstacles during automated insertion and extraction processes.
Innovation Solution
A box design with two main walls and two lateral walls, featuring an internal wall with a breakable tear line and folding flaps that separate from the wall, allowing for easy product insertion and simple leaflet extraction, where the internal wall is designed to fold and glue onto lateral walls, preventing hindrance during automated processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the box includes an internal wall defining a pocket for housing an illustrative leaflet, then the leaflet can be contained and protected, but the free edge of the internal wall and leaflet form obstacles that hinder product insertion into the box
Solution Approach 1:
The internal wall is segmented into multiple flaps (first flap, second flap, third flap) that can be independently folded and positioned. This segmentation allows the flaps to be arranged to facilitate product insertion while still containing the leaflet, resolving the contradiction between containment and ease of insertion.
Solution Approach 2:
The flaps are folded along folding lines to create three-dimensional configurations that clear the insertion path. By transforming the flat internal wall into a multi-dimensional structure with flaps extending in different directions, the design eliminates obstacles in the insertion dimension while maintaining containment functionality.
2Ease of operation
If the internal wall has a free edge to define the pocket opening, then the leaflet can be accessed, but the free edge creates obstacles during automated high-speed product insertion
Solution Approach 1:
The flaps are pre-folded and positioned along folding lines before product insertion occurs. This preliminary configuration ensures that the flaps are already in the correct position to guide products during high-speed automated insertion, eliminating the need for real-time adjustment and maintaining productivity.
3Ease of manufacture
If the internal wall structure is simplified for easy manufacturing, then production costs decrease, but the ability to facilitate both product insertion and leaflet extraction is compromised
Solution Approach 1:
The internal wall is divided into multiple flaps connected by folding lines, which can be easily formed from a single piece of cardboard through folding and gluing operations. This segmented design maintains manufacturing simplicity while enabling the flaps to be configured for both easy product insertion and leaflet extraction.
4Reliability
If the leaflet is retained securely in the pocket, then it remains protected, but extraction becomes difficult and requires extreme difficulty including opening, tearing and folding the box lid
Solution Approach 1:
The flaps are designed to be dynamic rather than fixed - they can be folded along folding lines to different positions. When extracting the leaflet, the flaps can be folded back to clear the extraction path, making removal easy. When containing the leaflet, the flaps can be positioned to secure it, thus adapting to different operational states.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A box the cavity of which is divided into two parts (30,31) by an internal wall (1) defining a pocket for housing an illustrative leaflet extractable by simply removing a portion (5) of the box wall external to the pocket. This removable portion has a projecting appendix (14) which is folded into the box above and into contact with the adjacent end of the leaflet of said internal wall.