Foldable Picture Frame Blank With Locking Wings for Flat Shipping
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Solution Overview
Problem
The existing process of producing picture frames is costly and complex, involving separate production of photos and frames, resulting in heavy products with high transportation and packaging challenges due to the inclusion of glass or transparent membranes, and requires manual mounting and drilling for hanging.
Innovation Solution
A foldable sheet material blank with wing portions and locking mechanisms that can be folded to form a tubular frame, allowing for easy assembly and disassembly, and printed with frame-simulating designs to resemble conventional photo frames, enabling a single-piece, lightweight, and cost-effective production of picture frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass or transparent membrane is added to cover the photo/frame, then the photo frame provides protection and a complete appearance, but the entire photo frame becomes very heavy
Solution Approach 1:
The patent uses printed frame-simulating patterns on the wing portions to create the visual appearance of a complete frame structure, copying the aesthetic function of traditional frames without the physical mass. The print patterns deceive the eye into perceiving depth and structure that isn't physically present, eliminating the need for heavy glass or membrane coverings.
2Manufacturing precision
If separate production of photo and frame with manual mounting is used, then the photo frame can be assembled with high quality control, but the production process becomes complicated and costly
Solution Approach 1:
The patent merges the photo, frame, and mounting mechanisms into a single integrated blank structure. The wing portions serve multiple functions simultaneously: they form the frame structure, provide mounting capabilities through folding and locking mechanisms, and display printed frame-simulating patterns. This integration eliminates separate production and manual assembly steps while maintaining quality control through standardized blank manufacturing.
Solution Approach 2:
The blank structure is designed to be self-assembling through predetermined fold lines and self-locking mechanisms. The wing portions automatically form the frame structure and secure the photo through their own geometric interlocking features without requiring external tools or complex assembly equipment, thereby simplifying the production process while ensuring consistent quality.
3Stability of the object's composition
If heavy photo frame is used, then the photo frame provides structural stability, but transportation fees increase and packaging becomes difficult
Solution Approach 1:
The patent segments the frame structure into collapsible wing portions that can be folded flat against the photo, transforming the three-dimensional stable structure into a two-dimensional compact package. The segmented design allows the frame to maintain structural integrity when assembled while reducing to a flat profile for efficient stacking and transportation, dramatically decreasing the quantity of shipping space required.
4Adaptability or versatility
If conventional photo frame with separate components is used, then each component can be optimized independently, but the assembly process requires manual mounting increasing cost and time
Solution Approach 1:
The patent incorporates preliminary action by pre-forming the wing portions with predetermined fold lines and pre-printing the frame-simulating patterns during blank manufacturing. The locking mechanisms are pre-positioned on the wing portions, so that when the blank is assembled, all components are already in their correct positions and orientations, eliminating the need for manual measurement, alignment, and mounting operations that would otherwise consume time and resources.
Data Source
Figure 1
Figure 1.1
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AI summary
A blank (10) for forming a one-piece picture frame with picture includes a blank body (12) having front and rear surfaces (14, 16), a central rectangular picture portion (20) formed thereon with a picture on the front surface (14). The blank (10) further includes four wing portions (30, 30') extending from the four margins (32, 32') of the rectangular picture portion (20) and the four wing portions (30, 30') are foldable into four rectangular tubular frame sections (50, 50'). Twelve locking mechanisms (60, 66, 70, 80) are used to lock the four frame sections (50, 50') in a folded position. A method of forming the picture frame with picture is also disclosed.