Folding Box With Integral Holding Panel For Heavy Auto Parts
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Solution Overview
Problem
Existing packaging solutions for heavy, fragile objects like auto parts are inefficient as they often require additional non-biodegradable and non-recyclable fillers or inserts, which can cause damage during transport and are difficult to dispose of without creating a mess.
Innovation Solution
A single-piece, biodegradable cardboard box with an integral holding panel that folds within the box to securely hold heavy objects, eliminating the need for additional packaging components and allowing for easy disassembly without spilling or shedding materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fillers or inserts are used to secure heavy objects, then the object is protected from movement and damage, but the packaging becomes non-recyclable and creates disposal mess
Solution Approach 1:
The patent combines the box structure and the holding/support structure into a single integrated cardboard construction. The holding panel is formed as an integral part of the box walls through folding and interlocking, eliminating the need for separate filler or insert components. This merger maintains object protection while ensuring the entire packaging is recyclable and biodegradable.
Solution Approach 2:
The holding panel is created by segmenting and folding portions of the box walls inward to form support surfaces and retaining structures. The box walls are divided into functional zones: outer walls for containment and folded inner panels for securing the object. This segmentation allows the packaging to provide both structural support and protection using only the box material itself.
2Reliability
If additional packaging components are added to secure the object, then the object is held in place, but the device complexity increases
Solution Approach 1:
The patent merges the functions of the box container and the object-holding structure into a single integrated design. The holding panel is formed by folding and interlocking sections of the box walls, creating both the container and the securing mechanism from one piece of material. This eliminates multiple separate components and simplifies the overall packaging structure.
Solution Approach 2:
The box walls serve multiple functions: they provide the container structure, form the holding panel through folding, create support surfaces, and form retaining edges. This multi-functionality reduces the need for specialized components, as the same material serves both containment and securing purposes.
3Device complexity
If heavy objects are loosely packaged, then the packaging is simple, but the object moves during transport causing damage
Solution Approach 1:
The holding panel is designed to be formed dynamically during the packaging process by folding and interlocking the box walls inward. This creates an adaptive securing structure that conforms to the object being packaged. The dynamic formation of the holding panel allows the simple box to transform into a secure container that prevents movement during transport.
Solution Approach 2:
The box is pre-designed with fold lines and interlocking features that enable the holding panel to be formed in advance of object insertion. The structure is prepared during manufacturing with predetermined folding zones, allowing the holding mechanism to be created before the object is placed, ensuring immediate protection upon assembly.
Data Source
AI summary
A single blank for forming a box, the blank comprising a first panel, a second panel, a third panel and a fourth panel. The first panel is foldably connected to a folding support structure that is foldable and insertable inside the box. The folding support structure comprises a first inner flap which is connected to the first panel along a first inner flap fold line, a second inner flap which is connected to the first inner flap along a first inner flap second fold line, a first integral holding panel which is connected to the second inner flap along a first edge fold line, and a second integral holding panel which is foldably connected to the first integral holding panel along a second integral holding panel fold line.