Folded Display Container With Integral Shelves for Fast Erection
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Solution Overview
Problem
Conventional knocked-down-flat (KDF) container designs are limited in complexity and require extensive assembly steps due to the need for separate discrete parts, which increases production costs and complexity, making it difficult to create intricate structures without adding numerous parts and assembly complications.
Innovation Solution
A folded and glued container design featuring a movable shelf-raising panel that is articulated with shelf panels, allowing for the creation of complex structures within a single integral die-cut blank, where the shelf-raising panel is attached to the shelf panels during the fold and glue assembly process, enabling easier erection and reducing the need for separate parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate discrete parts are used for shelves and container walls, then assembly flexibility is improved, but device complexity and assembly time increase
Solution Approach 1:
The patent combines separate discrete parts (container walls and shelves) into a single integral die-cut blank. The shelf-raising panel is integrally formed with the container walls from the same sheet material, eliminating the need for separate shelf components and reducing assembly steps while maintaining design flexibility.
Solution Approach 2:
The integral blank is segmented into functional zones including container walls and shelf-raising panels that can be independently folded and positioned. This segmentation allows different portions of the single blank to perform different functions, achieving complexity reduction while preserving assembly flexibility.
2Productivity
If conventional fold and glue process is used for integral blanks, then manufacturing efficiency is improved, but erection complexity increases for complex structures
Solution Approach 1:
The fold and glue process performs preliminary folding and positioning of the shelf-raising panel during manufacturing. Adhesive is applied to preselected surfaces and panels are folded around fold joints while in the KDF state, preparing the structure for easier final erection without requiring complex assembly steps later.
Solution Approach 2:
The shelf-raising panel is designed to be relatively movable during the transition from KDF to erected configuration. The panel can be displaced to cause shelf panels to articulate into their final positions, enabling dynamic transformation from collapsed to erected state with minimal manual intervention.
3Adaptability or versatility
If multiple separate parts are required for container assembly, then design flexibility is improved, but inventory management and assembly time increase
Solution Approach 1:
Multiple functional components (container walls, shelves, reinforcing elements) are merged into a single integral die-cut blank. This eliminates the need for separate inventory management of multiple parts while maintaining the design flexibility to create varied container configurations from the same blank through different folding and positioning sequences.
Data Source
AI summary
A rectilinear folded and glued container with tiered shelves has multiple shelf panels cut out of a front panel with which the shelf panels, and main container front, side and back panels are integrally connected. The container has an internally placed shelf-raising panel that is attached to the shelf panels as part of a fold and glue processing technique that produces a knocked down flat container to be erected. The shelf raising panel preferably is an integral panel that is separate from the main container panels so as to be relatively movable, and is affixed to the shelf panels. Displacing or translating the shelf-raising panel during erection of the container from its knocked-down-flat configuration articulates the shelves into position. The shelf raising panel can be captured between top and bottom ends of the erected container, thus fixing the erected container and articulated shelves in a rigid shape.