Cellulose Display Container with Air Cell Panel Assembly
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Solution Overview
Problem
Existing cellulose-based containers and blanks lack efficiency in storage and display due to inflexibility and additional requirements for stacking strength and void fillers, especially in retail environments where space optimization and easy assembly are crucial.
Innovation Solution
A single piece foldable container blank made from cellulose-based materials like wood pulp, scored and perforated to form a container with variable inner volume, eliminating the need for additional inserts and void fillers, and providing enhanced stability through 'air cells' and a double bottom panel design for improved pallet space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional cellulose-based containers are used, then basic storage function is provided, but additional inserts and void fillers are required, increasing device complexity
Solution Approach 1:
The container blank is segmented into multiple functional zones including air cells, display panels, and structural panels. This segmentation allows each zone to perform specific functions (cushioning, display, structural support) eliminating the need for additional inserts and void fillers, thereby reducing device complexity while maintaining reliability
Solution Approach 2:
The container blank integrates multiple functions into a single structure: the air cells provide both cushioning and void filling, the display panels enable product presentation, and the structural panels provide stacking strength. This multi-functionality eliminates the need for separate components, reducing device complexity while maintaining all required performance characteristics
2Ease of manufacture
If inflexible container design is used, then manufacturing simplicity is maintained, but pallet space optimization is reduced
Solution Approach 1:
The container blank incorporates foldable panels and air cells that can be compressed and deformed to conform to irregular product shapes and optimize pallet space. This dynamic design allows the container to adapt its volume and shape while maintaining ease of manufacture through a single-piece construction that requires no additional assembly steps
3Reliability
If additional inserts and void fillers are added, then product protection is improved, but assembly time increases
Solution Approach 1:
The air cells, display panels, and structural elements are merged into a single integrated blank that is formed from one piece of cellulose-based material. This integration eliminates the need to assemble multiple separate components, significantly reducing assembly time while maintaining product protection through the built-in air cell cushioning and structural support
4Productivity
If single-piece foldable blank is used, then assembly efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The container blank is pre-formed with all necessary fold lines, air cell structures, and panel configurations during the initial manufacturing process. This preliminary action ensures that the blank is ready for immediate assembly without requiring complex alignment or adjustment during assembly, thereby improving assembly efficiency while managing manufacturing precision requirements through standardized forming processes
Data Source
AI summary
The embodiments of the present invention provide a blank foldable material that may be configured to form a container. When formed, the container is self-locking and includes air cell structure that allows for a container with a constant outside volume to have a variable inside volume. The air cell structure container functions to prevent telescoping of vertically stacked container and for strength and stability. The container may be partially assembled for shipping and hand set into final assembly as needed.