Fiber Reel-in-Box Packaging with Interlocking Tabs
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Solution Overview
Problem
Existing reel-in-box packaging for communications cable lacks efficient assembly, structural integrity, and ease of shipment, particularly when handling fiber optic cables, as it requires additional labor and materials for closure and lacks a convenient method to assess and rewind cable lengths without opening the package.
Innovation Solution
A cable packaging arrangement featuring easily assembled tabs for closure, fold lines for flat shipment, a perforated side for securing cable ends, and a large payout window for visual assessment and rewind of fiber optic cable without opening the package, providing structural stiffness and eliminating the need for external fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional reel-in-box packaging is used, then cable can be stored and shipped, but assembly requires additional labor and materials for closure
Solution Approach 1:
The packaging structure is divided into modular components with tabs at each end that can be independently assembled. The tabs are shaped to interlock with complementary features on the box body, allowing sequential assembly without requiring external fasteners or complex closure mechanisms.
Solution Approach 2:
The tabs are designed with self-aligning and self-locking features that enable automatic engagement when brought together. The tab geometry includes tapered leading edges and mating recesses that guide proper orientation and secure the assembly through friction and geometric interlocking, eliminating the need for additional fastening materials or operations.
2Strength
If traditional reel-in-box packaging is used, then cable can be stored, but structural integrity is insufficient to bear cable weight
Solution Approach 1:
Reinforcement ribs and structural features are pre-formed as integral parts of the box during manufacturing. These features include internal support ribs, flanged tabs with stiffening elements, and pre-positioned cable management structures that provide mechanical strength before the cable is even placed in the package.
Solution Approach 2:
The packaging structure utilizes composite construction combining rigid outer walls with internal reinforcement elements. The tabs feature layered or ribbed geometries that provide high strength-to-weight ratio, and the overall structure integrates different material properties to withstand cable weight while maintaining assembly simplicity.
3Ease of manufacture
If traditional reel-in-box packaging is used, then cable can be shipped, but shipment requires non-flat configuration
Solution Approach 1:
The packaging structure incorporates fold lines and hinge connections that allow the box to transition between a three-dimensional shipping configuration and a flat, collapsed state. The tabs and panel connections are designed to flex and compress, enabling the structure to nest flat for efficient storage and transport when not in use.
4Ease of operation
If traditional reel-in-box packaging is used, then cable can be stored, but cable end securing is difficult
Solution Approach 1:
The tab structure includes integrated cable securing features where the cable end is inserted into a recess or slot formed in the tab itself. The tab geometry creates friction retention and geometric locking that secures the cable end without requiring separate clips, ties, or fastening operations.
5Ease of operation
If traditional reel-in-box packaging is used, then cable can be stored, but visual assessment of remaining cable requires opening the package
Solution Approach 1:
The box includes a localized transparent or translucent window section that provides visual access to the cable reel and remaining cable length. This window is positioned to offer a clear view of the cable spool while maintaining the integrity and closure of the rest of the package, allowing users to assess cable inventory without opening the box.
Data Source
AI summary
Aspects and techniques of the present disclosure relate to a cable packaging arrangement (e.g., reel-in-box package) including a plurality of tabs appending to the top and bottom portions of the arrangement which are individually shaped to be easily assembled together, respectively, so that the top and bottom portions of the cable packaging arrangement will be closed.