Custom Packaging Box with Segmented Lid for Variable Item Sizes
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Solution Overview
Problem
Existing systems for creating custom-sized open packaging boxes and separate closing lids from cardboard face limitations, including restricted maximum box height and width, which restricts the optimal packaging of items of varying sizes and numbers, and lack stability and ease of use due to complex structures and material handling issues.
Innovation Solution
The solution involves allowing side panels of the box to have a height smaller than end panels and compensating by increasing the lid's side panel height to prevent lateral openings, enabling the creation of stable boxes without the mentioned restrictions, allowing for efficient packaging of items of varying sizes and numbers, and facilitating the addition of loose fill materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the maximum box height and width are restricted based on traditional cardboard blank structures, then the manufacturing process remains simple, but the adaptability to package items of varying sizes is reduced
Solution Approach 1:
The invention divides the traditional integrated box structure into two separate components: an open box body and a separate closing lid. This segmentation allows each component to be optimized independently - the box can be designed for maximum stability and item accommodation, while the lid can be designed for ease of closure and different dimensional requirements, thereby increasing adaptability without proportionally increasing overall complexity
Solution Approach 2:
The separate lid design serves multiple functions: it provides closure for the box, can be used as a carrying handle when detached, and allows for flexible packaging configurations. This multi-functionality increases the system's adaptability to various packaging needs while maintaining relatively simple individual component structures
2Adaptability or versatility
If complex structures with numerous perforated lines and cuts are used to create custom-sized boxes, then various box sizes can be formed, but the stability of the box and lid is reduced
Solution Approach 1:
The invention applies different structural qualities to different parts of the packaging system. The box body uses a simple, stable structure with minimal cuts and perforations for maximum structural integrity, while the lid uses a separate, optimized structure. This local differentiation allows custom sizing capability without compromising the stability of either component
Solution Approach 2:
By separating the box and lid into distinct components with independent structures, each can be optimized for its specific function - the box for stability and item containment, the lid for closure and handling - thereby maintaining stability while achieving custom sizing adaptability
3Volume of stationary object
If traditional box structures are used, then manufacturing is straightforward, but the volume efficiency and optimization for transportation costs are reduced
Solution Approach 1:
The invention enables dynamic customization of box dimensions through the separate lid system, allowing the box volume to be precisely optimized for each item set being packaged. This dynamic adaptability improves volume efficiency and transportation optimization while the standardized base structure maintains ease of manufacture through automated cutting and folding processes
4Productivity
If items and loose fill material are placed together on the blank during folding, then packaging is efficient, but the loose fill material falls off or flies about
Solution Approach 1:
By separating the box construction into a stable base structure and a separate lid, the invention creates a contained environment where loose fill material can be securely placed inside the box body before the lid is attached. This segmentation maintains high packaging speed while preventing loose fill material from falling or flying during the folding and closing process
Solution Approach 2:
The separate lid design allows loose fill material to be preliminarily placed and secured within the box body before the lid is attached. This preliminary action ensures that loose fill material is contained and controlled before the final closing operation, maintaining both productivity and reliability
Data Source
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AI summary
Method and system for making custom-sized open packaging boxes from cardboard having a width WCBB and corresponding separate closing lids from cardboard having a width WCBL, the cardboard being continuously supplied to a system comprising structure for cutting, creasing and folding the cardboard to form custom-sized boxes and corresponding lids such that each box comprises a rectangular bottom panel having four edges, a first and a second rectangular end panel joined via respective crease lines to opposite edges of said bottom panel, a first and a second rectangular side panel joined via respective crease lines to opposite edges of said bottom panel, two first and two second rectangular corner panels, the first corner panels joined via respective crease lines to opposite edges of the first end panel, and the second corner panels joined via respective crease lines to opposite edges of the second end panel, each lid comprises a rectangular top panel having four edges, a first and a second rectangular end panel joined via respective crease lines to opposite edges of said top panel, a first and a second rectangular side panel joined via respective crease lines to opposite edges of said top panel, optionally two first and two second rectangular corner panels, the first corner panels joined via respective crease lines to opposite edges of the first end panel and the second corner panels joined via respective crease lines to opposite edges of the second end panel, said method comprising: a step of obtaining information on the desired minimum inner dimensions length LD, height HD and width WD of a box to be created, a calculating step of calculating the dimensions of the panels of a box and of the panels of a lid on the basis of the desired minimum dimensions taking into account predetermined optimization criteria, and a step of creating the box and the lid, wherein said calculating step comprises allowing the inner height of the side panels of the box to be smaller than the desired inner height of the box if (WD + 2 TCBB + 2HD) > (WCBB - MB), wherein MB denotes an optional minimum margin that is cut off at the sides of the cardboard supplied and wherein TCBB denotes a material dependent correction factor generally corresponding to the thickness of the cardboard used for the box, and/or if 2HD > LD and choosing the inner height of the side panels of the lid template so that the inner height of the side panels of the box plus the inner height of the side panels of the lid equals at least the desired height.