Collapsible Return Box Flap Structure for Tape-Free Resealing

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Solution Overview

Problem

The process of returning items purchased online is cumbersome due to the need to repack the items in the original box, which often requires additional packaging tape and can result in damage to the box, making it unsuitable for shipping.

Innovation Solution

A dual-use box with a primary and secondary flap system, featuring a primary adhesive and a secondary adhesive with peelable backing, allowing for easy opening and resealing without additional tape, and a collapsible design for efficient storage and shipping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the box is opened for unpacking items, then the items can be accessed, but the box becomes damaged and unsuitable for shipping returns

Engineering Contradiction:
Improveunpacking itemsVSAvoidbox integrity for shipping
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The top panel is divided into multiple flaps (first flap, second flap, third flap) that can be independently opened and closed. This segmentation allows the box to be opened for unpacking while maintaining the ability to reseal securely for return shipping.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Adhesive strips are pre-applied to the flaps before the box is used. This preliminary preparation enables easy opening and closing without requiring additional tape or sealing materials when the box needs to be resealed for returns.

Inventive Principle:
Principle #10Preliminary action

2Reliability

If additional packaging tape is used to seal the box for returns, then the box can be securely closed, but the complexity and cost of the returning process increases

Engineering Contradiction:
Improvebox sealing for shippingVSAvoidrepackaging process
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

Adhesive strips are pre-applied to the flaps during box manufacturing. This preliminary action eliminates the need for customers to purchase and apply additional packaging tape when sealing the box for returns, simplifying the repackaging process.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The box provides its own sealing capability through pre-applied adhesive strips on the flaps. The box essentially seals itself when the flaps are folded into place, without requiring external tape or additional sealing materials.

Inventive Principle:
Principle #25Self-service

3Strength

If the box is made rigid for structural strength, then it provides good protection, but it occupies more storage space when collapsed

Engineering Contradiction:
Improvebox structural integrityVSAvoidstorage space when collapsed
Core Design Contradiction:
StrengthVSVolume of moving object

Solution Approach 1:

The box incorporates a collapsible bottom structure that can transition between an expanded configuration (for shipping and storage) and a collapsed configuration (for compact storage when empty). This dynamic structure maintains structural integrity when needed while minimizing volume when collapsed.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The collapsible bottom panels can be folded nested within each other when the box is emptied, significantly reducing the volume occupied during storage while maintaining full structural strength when expanded for use.

Inventive Principle:
Principle #7Nested doll (Nesting)

Data Source

PatentUS12595091B2Method of collapsing a collapsible box
Publication Date: 2026.04.07 PRATT CORRUGATED HOLDINGS INC
  • US12595091B2 patent drawing
  • US12595091B2 patent drawing
  • US12595091B2 patent drawing

AI summary

A method of collapsing a collapsible box includes providing the collapsible box, the collapsible box comprising: a plurality of side panels including a first side panel and a second side panel, each of the plurality of side panels defining a side panel top edge; a box bottom; and a box top comprising a plurality of top panels including a first top panel extending from the side panel top edge of the first side panel and a second top panel extending from the side panel top edge of the second side panel, the second top panel comprising an overlapping portion; folding the first side panel towards the second side panel to confront the first side panel with the second side panel; and folding the overlapping portion of the second top panel over a top panel top edge of the first top panel.