Cardboard Box Lid Closure Using Partially Folded Flaps
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Solution Overview
Problem
Existing systems face challenges in automatically closing custom-sized cardboard boxes with varying shipment sets, as the boxes often lack stability due to items not fully filling the box, leading to misalignment issues between the lid and the box, and the inherent properties of cardboard result in tolerances and deviations that complicate the attachment of pre-folded lids.
Innovation Solution
The method involves using partially folded flaps of the lid as guiding elements for alignment, with elastic suction cups to gently push the lid onto the box, allowing for proper alignment and secure attachment, even when the box is not fully filled or has deviations in dimensions, and utilizing a two-step process for folding the flaps to ensure accurate placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom-sized boxes are created to fit varying shipment sets, then the boxes can accommodate different item sizes and quantities, but the boxes lack stability when items do not fully fill the box
Solution Approach 1:
The patent applies preliminary action by pre-folding the lid flaps to predetermined angles (e.g., 45 degrees) before attachment. This preliminary folding creates guiding elements that ensure proper alignment and stability during the closing process, compensating for the instability caused by partially filled boxes.
2Ease of manufacture
If cardboard material is used for boxes and lids, then the material is easy to manufacture and handle, but the inherent properties of cardboard result in tolerances and deviations that complicate attachment
Solution Approach 1:
The patent applies parameter changes by transforming the rigid dimensional parameters into flexible angular parameters. Instead of requiring precise dimensional matching, the system uses fold angles (e.g., 45 degrees) as the critical parameter, which is much easier to control and compensate for variations in cardboard thickness and tolerances.
Solution Approach 2:
The pre-folding of flaps to predetermined angles serves as a preliminary action that establishes alignment references before the actual attachment process, compensating for dimensional variations in the cardboard material.
3Extent of automation
If pre-folded lids are used for automatic packaging, then the packaging process can be automated, but misalignment issues between the lid and the box occur due to tolerances and deviations
Solution Approach 1:
The system performs preliminary folding of the lid flaps to predetermined angles before the lid is placed on the box. This preliminary action creates self-aligning guiding elements that automatically correct for misalignment issues during the automated attachment process.
Solution Approach 2:
The partially folded flaps act as intermediary guiding elements between the lid and the box. These flaps provide physical references that guide the alignment process, mediating the connection between the lid and box even when dimensional tolerances exist.
4Adaptability or versatility
If the box is not fully filled with items, then varying shipment sets can be packaged, but the box lacks stability for secure lid attachment
Solution Approach 1:
The flaps are preliminarily folded to predetermined angles (e.g., 45 degrees) before attachment, creating stable geometric structures that provide reliable alignment and attachment references even when the box is not fully filled with items.
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 approach ensures reliable and efficient automatic closure of custom-sized cardboard boxes by maintaining box stability and improving the alignment and adhesion of the lid, even with varying item sizes and quantities, enhancing the packaging process for shipment sets.
Implementation Method 1
elastic suction cups to gently push the lid onto the box
Implementation Method 2
elastic suction cups to gently push the lid onto the box
Data Source
AI summary
A method for automatically closing an open packaging box with a cardboard lid, said box comprising a polygonal bottom panel defined by three or more bottom panel edges and sidewalls joined over respective crease lines to said bottom panel edges, each sidewall forming a substantially right angle with the bottom panel, said lid comprising a polygonal top panel defined by three or more top panel edges and corresponding to the bottom panel of the box to be closed and flaps joined over respective crease lines to said top panel edges and adapted for being folded onto a corresponding one of said sidewalls, the method comprising a step of folding each flap along the respective crease line partially towards a position, in which the flap forms a substantially right angle with said top panel and placing the lid above said box such that the top panel and the bottom panel are substantially aligned and such that, seen onto each sidewall, each flap overlaps one of the sidewalls, a step of releasing the lid allowing it to be guided by the partially folded flaps into a position on the box, in which the top panel and the bottom panel are aligned, and a step of folding each flap onto the respective sidewall fully into said position, in which the flap forms a substantially right angle with the top panel.