Foldable Polymer Container with Hinge and Locking Flaps
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Solution Overview
Problem
Current foldable containers are cumbersome to convert between deployed and collapsed states, often unstable under heavy loads, and are not suitable for industrial or retail settings due to limited weight capacity and complex construction.
Innovation Solution
A foldable container with a cuboid form in the deployed state, made from synthetic polymers, featuring a base, side walls attached by hinge joints, and a repeatable locking mechanism with mechanical transmissions that allow for easy conversion between states without changing grip, ensuring stability and ease of use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a foldable container is designed with multiple parts and complex construction, then it can achieve foldability, but the construction becomes complicated and the connection between parts becomes weak
Solution Approach 1:
The container is divided into multiple parts (base, side walls, flaps) that can be independently manufactured and then assembled. Each part is segmented to allow for hinge connections while maintaining overall structural integrity. This segmentation enables foldability without requiring complex construction, as each segment can be optimized independently.
Solution Approach 2:
Multiple functional elements are merged into a single integrated structure. The base, side walls, and flaps are designed as separate components that assemble into a unified container system. The hinge joints and locking mechanisms are integrated into the existing structure rather than being added as separate complex assemblies, reducing overall construction complexity.
2Stability of the object's composition
If a foldable container uses a mechanism to hold it in the deployed state, then it can maintain stability, but the weight capacity is limited by the construction or mechanism
Solution Approach 1:
The container employs dynamic locking mechanisms that engage when the container is in the deployed state and disengage when collapsed. The flaps can be locked into position using simple latch mechanisms that provide stable holding without limiting weight capacity. The hinge joints are designed to support the full weight of the container and its contents while maintaining stability through the locking action.
Solution Approach 2:
The locking mechanism is designed to automatically engage and lock the flaps in place when the container is positioned correctly, without requiring additional external support structures. The weight of the container itself and the mechanical interaction between flaps and locking mechanisms provide the necessary stability, eliminating the need for complex support systems that would limit weight capacity.
3Adaptability or versatility
If a foldable container requires many manipulations to fold between states, then it can achieve conversion, but it becomes cumbersome and difficult to use
Solution Approach 1:
The flaps are pre-positioned and designed to automatically align with the locking mechanisms when the container is collapsed. The hinge joints are pre-configured to guide the folding motion, so that when a user begins to collapse the container, the flaps naturally move into the locked position without requiring multiple separate manipulations. This preliminary arrangement of components enables smooth, intuitive conversion.
Solution Approach 2:
The locking mechanism is designed to automatically engage when the flaps are positioned correctly during folding, without requiring the user to perform additional locking actions. The mechanical interaction between the flaps and locking elements occurs automatically as part of the folding motion itself, reducing the number of manipulations required and making the container easy to use.
4Adaptability or versatility
If a foldable container is made from different parts, then it can achieve foldability, but the connection between parts becomes a weak point requiring extra care
Solution Approach 1:
The container is segmented into base, side walls, and flaps that are connected through hinge joints designed to accommodate the full range of motion and loading conditions. Each connection point is segmented to allow for independent movement while maintaining strong overall connection through the hinge mechanism and locking system.
Solution Approach 2:
The container utilizes composite construction with the base, side walls, and flaps made from appropriate materials for their specific functions. The hinge joints and locking mechanisms are designed to work together as a composite system that provides reliable connections. The materials and construction methods are selected to ensure that the connections between parts are as strong as the parts themselves, eliminating weak points.
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 container can hold heavy loads, is easy to manipulate, and maintains stability in the deployed state while collapsing flat for storage, addressing the limitations of existing foldable containers by simplifying the conversion process and enhancing durability.
Implementation Method 1
each of the side walls (4, 5, 6, 7) is attached to the base (3) by a separate hinge joint
Implementation Method 2
at least one first side wall (4, 5), preferably both first side walls (4, 5) is each attached to an adjacent second side wall (6, 7) by a mechanical transmission (22, 23, 24, 25) for transfer of force from the pair of opposing first side walls (4, 5) to the pair of opposing second side walls (6, 7) during transition between the collapsed state (2) and the deployed state (1)
Implementation Method 3
each foldable flap (8, 9) clamps at least one, preferably at least two mechanical transmission (22, 23, 24, 25) against at least one side wall (4, 5, 6, 7), when said foldable flap is locked against at least one of the sidewalls (4, 5, 6, 7), by the repeatable locking mechanism in the deployed state (1)
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention provides a foldable container wherein: - the container comprises: - a base (3); - a pair of opposing first side walls (4, 5); - a pair of opposing second side walls (6, 7); - each of the side walls is attached to the base by a separate hinge joint; - the foldable container is made from a polymer; further comprising: - a pair of foldable flaps (8, 9), each attached to an upper edge (10, 11) of each of the first side walls by a hinge joint; - repeatable locking mechanism configured to lock each of the foldable flaps against at least one side walls.