Display base, blank and method of constructing the base
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Solution Overview
Problem
Conventional display base manufacturing is inefficient due to complex assembly processes, high material usage, and low production rates, with users facing difficulties in assembling the base without prior knowledge of the correct sequence and requiring multiple machines for folding and gluing.
Innovation Solution
A redesigned one-piece blank with directly adjacent fixing tabs that allow for intuitive assembly, reduced material usage, and increased production efficiency, featuring connected fixing tabs and side walls that guide each other during assembly, eliminating blockages and enabling assembly with a single machine to produce several thousand bases per hour.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional one-piece blanks are used with separate fixing tabs, then the base can be assembled, but the assembly process becomes complex and non-intuitive requiring specific sequences and prior knowledge
Solution Approach 1:
The patent merges directly adjacent fixing tabs into a single connected structure instead of separate tabs. This combination allows the fixing tabs to guide each other during assembly automatically, eliminating the need for complex assembly sequences and making the process intuitive for users without prior knowledge.
Solution Approach 2:
The connected fixing tabs perform self-guidance during assembly, where each tab automatically finds its correct position and orientation without external guidance or complex sequencing instructions. The structure serves itself by providing inherent assembly guidance through the physical connection between tabs.
2Quantity of substance
If conventional cutting patterns are used for one-piece blanks, then all necessary flaps and walls can be formed, but a lot of material is consumed
Solution Approach 1:
The patent optimizes the segmentation of the one-piece blank by carefully planning where cuts and folds occur. The cutting pattern is designed to minimize waste by precisely positioning flaps, walls, and fixing tabs to utilize the maximum amount of material from the blank, reducing unnecessary material consumption while maintaining all required functional elements.
3Productivity
If multiple machines are used for folding and gluing side walls and flaps, then the base can be manufactured, but production output is very low at only a few bases per minute
Solution Approach 1:
The patent combines multiple manufacturing operations into a single machine process. The redesigned blank allows folding and gluing operations to be performed in sequence by one machine rather than requiring multiple separate machines, dramatically increasing production output to several thousand bases per hour while simplifying the manufacturing system.
Solution Approach 2:
The manufacturing process achieves continuity by designing the blank so that folding and gluing operations can proceed without interruption in a single machine pass. The connected fixing tabs and optimized flap arrangements allow continuous processing without the need to stop for repositioning or complex multi-machine coordination.
4Stability of the object's composition
If locking tabs are positioned in difficult to access cavities, then the base structure is stable, but assembly becomes difficult or impossible if tabs are not correctly positioned
Solution Approach 1:
The connected fixing tabs are designed to perform preliminary guidance action during assembly, automatically positioning themselves into the correct cavities before final locking occurs. This preliminary self-positioning ensures that tabs are correctly placed before the stability-critical locking phase, eliminating assembly difficulties while maintaining structural stability.
Data Source
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AI summary
A one-piece blank (10) made of a foldable material, such as cardboard, in particular for a base (12), wherein the blank (10) comprises: outer side walls (14) which are connected to each other via first fold lines (22) which extend in a longitudinal direction (L); inner side walls (16), wherein the inner and outer side walls (14, 16) are paired together such that paired side walls (14-1, 16-1; 14-2, 16-2; 14-3, 16-3; 14-4, 16-4) are opposite each other; Cover flaps (18) arranged in the longitudinal direction (L) between the outer and inner side walls (14, 16), wherein the cover flaps (18) are connected to the outer and inner side walls (14, 16) via second and third fold lines (24, 26) extending in a width direction (B); and fixing flaps (20), wherein the fixing flaps (20) are connected to the inner side walls (16) via fourth fold lines (28) extending in the longitudinal direction (L).