Foldable Box Locking Mechanism with Overload Protection
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Solution Overview
Problem
Foldable boxes face challenges in achieving low stacking height, lightweight design, stability, ease of cleaning, and robustness while preventing damage from operational errors, especially when transporting food and vegetables.
Innovation Solution
The design incorporates protrusions and spring-pretensioned locking mechanisms with inclined contact surfaces for vertical latching, allowing for easy operation and emergency release, along with a specialized hinge arrangement for non-positive connections that absorb forces and facilitate easy dismantling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the locking mechanism is made robust to survive loading/unloading processes, then the stability and durability of the box are improved, but the complexity of the hinge mechanism increases and the risk of destruction from operational errors remains
Solution Approach 1:
The locking mechanism is divided into separate functional elements: a hinge element with a cam profile for force absorption, a locking element for positive latching, and a release element for easy opening. This segmentation allows each component to be optimized independently - the hinge element absorbs forces while the locking element provides stability, reducing overall complexity while improving reliability.
Solution Approach 2:
The cam profile on the hinge element is designed to absorb excess forces before they can damage the locking mechanism. When forces exceed a predetermined threshold, the cam profile allows controlled movement that dissipates energy, protecting the locking elements from destruction while maintaining box stability during normal operation.
2Ease of operation
If the side walls are easily detachable from the floor for transport, then the ease of operation is improved, but the capability to carry high loads is reduced
Solution Approach 1:
The connection between side walls and floor transitions from a static rigid connection to a dynamic system that adapts to operational needs. During transport, the hinge mechanism allows easy detachment when forces are applied. During loading, the locking elements engage positively to provide rigid connection for high load-bearing capability. This dynamic behavior is achieved through the cam profile and spring-pretensioned locking elements.
Solution Approach 2:
The mechanical properties of the connection change based on operational conditions. The spring-pretensioned locking elements provide high stiffness and load-bearing capability when engaged. When forces exceed the predetermined threshold or during dismantling, the system transitions to a more flexible state allowing easy detachment. This parameter change enables the same connection to satisfy both ease of operation and load-bearing requirements.
3Strength
If the locking mechanism uses large contact surfaces for stable latching, then the strength of connection is improved, but the force required for opening increases
Solution Approach 1:
The locking mechanism uses periodic spring force to maintain continuous pressure on the locking elements, ensuring strong latching connection. The spring-pretensioned elements provide periodic engagement that maintains connection strength without requiring continuous high force to keep the box closed. This periodic action allows easy opening while maintaining strong latching.
Solution Approach 2:
The cam profile acts as an intermediary element between the hinge and locking mechanisms. It mediates the force transmission by absorbing excess forces and converting them into controlled movement. This intermediary allows the locking elements to engage with sufficient force for strong latching while the cam profile manages the force requirements for opening through its geometric profile.
4Stability of the object's composition
If the box uses large flat planes for stability, then the stability of the box is improved, but the ease of cleaning is reduced due to food rests being trapped
Solution Approach 1:
The box structure uses local quality variations to simultaneously achieve stability and ease of cleaning. The hinge elements and locking mechanisms use localized geometric features (cams, profiles, contact surfaces) that provide stability where needed without creating large flat planes that trap food. The overall structure maintains stability through the distributed locking mechanism while local areas have optimized geometries that facilitate cleaning.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables a stable, lightweight, and easy-to-clean foldable box that maintains structural integrity even under incorrect operation, ensuring efficient handling and prolonged use without damage to components.
Implementation Method 1
a spring-pretensioned locking mechanism arranged at the outside of the transverse side exterior wall, which has in the upfolded state a snap-in element movable in a vertical direction with respect to the surface of the floor
Implementation Method 2
the protrusion and/or the snap-in element have contact surfaces which are inclined with respect to the vertical direction in the upfolded state such that the locking mechanism, when exceeding a predetermined force directed inwards acting upon the transverse side exterior wall opens against its spring-pretensioning
Data Source
AI summary
A foldable box includes a floor and two longitudinal and transverse side exterior walls each lying opposite in pairs and foldable relative to the floor, each longitudinal side exterior walls—including a protrusion at a transverse side end extending toward the transverse side exterior walls when upfolded, limiting foldability of the transverse side exterior walls to the outside. Each transverse side exterior wall including a locking mechanism at the outside of the transverse side exterior wall, including when upfolded, a snap-in element movable in a vertical direction relative to the floor surface, latchable with the protrusion. The protrusion and/or the snap-in element includes contact surfaces, inclined relative to the vertical direction when upfolded wherein the locking mechanism opens against a spring pretensioning when exceeding a predetermined inward force acting upon the transverse side exterior wall.