Foldable Packaging Container With Integral Lid And Base
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Solution Overview
Problem
Current packaging technologies fail to simplify the assembly process while minimizing material usage and providing a decorative exterior and interior from a single continuous sheet, with existing solutions not addressing how to form a container with a lid from the same material as the box compartment.
Innovation Solution
A container design that utilizes a flat blank with fold lines to form both the base and lid portions, where at least one wall is integrally connected to both, allowing the container to be formed from a single continuous sheet, enabling the lid to be formed from the same material as the box compartment and allowing for decorative printing on the exterior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a container is formed from multiple separate flat sheets (cover and insert), then the decorative exterior and structural interior can be provided separately, but the assembly process becomes more complex and requires more materials
Solution Approach 1:
The patent combines the cover and insert into a single continuous flat blank that forms both the base portion and lid portion when folded. This merging eliminates the need for separate components, simplifying assembly while reducing material usage. The single blank includes fold lines that define the base, walls, and lid portions, allowing all components to be integrated from one piece of material.
2Loss of substance
If the lid is formed from separate material than the box compartment, then structural integrity can be optimized independently, but material usage increases and assembly simplification is lost
Solution Approach 1:
The lid portion and base portion are merged into a single continuous blank, eliminating the need for separate lid material. The integrated design reduces material usage while maintaining structural integrity through the integral connection of walls to both base and lid portions.
Solution Approach 2:
The single blank is segmented into functional zones (base portion, wall portions, lid portion) through fold lines and cut lines, allowing each section to serve its structural purpose while remaining part of the same continuous material.
3Device complexity
If the container is formed from a single continuous sheet, then material usage is reduced and assembly is simplified, but forming a lid from the same sheet becomes structurally challenging
Solution Approach 1:
The patent transitions from a two-dimensional flat blank to a three-dimensional container structure through folding. The lid portion is formed by folding the blank along designated fold lines, creating vertical and horizontal dimensions that enable lid formation from the same continuous material as the base.
Solution Approach 2:
The continuous blank is segmented into distinct functional areas (base, walls, lid) through fold lines and cut lines, allowing the lid to be formed from the same material while maintaining structural differentiation between components.
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
The solution enables a container that can be shipped and stored flat, simplifies assembly, reduces material usage, and provides a decorative exterior and interior, while maintaining structural integrity and aesthetic appeal.
Implementation Method 1
The container is formed from a blank which is initially flat with a plurality of fold lines
Data Source
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AI summary
A container (10) having both a one-dimensional configuration before it is formed into its three-dimensional configuration. A blank (36) is used to form the container and is initially flat with a plurality of fold lines (60). The container includes a base portion (12) with a plurality of edges (14) along its perimeter, a lid portion (30) which is distanced from and parallel to the base portion, and a wall projecting orthogonally from each edge forming a plurality of walls (20, 22, 24). At least one wall is integrally connected to both the base portion and the lid portion.