Height-Variable Box Assembly via Adjustable Fold Lines
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Solution Overview
Problem
Existing height-adjustable box technologies cannot freely adjust their size to accommodate products of varying heights, leading to inefficiencies in packing and increased costs due to larger box sizes and gaps.
Innovation Solution
A method and device that form first and second fold lines on a base and cover sheet, allowing the sheets to be bent and bonded in a specific manner to adjust the box height based on product dimensions, with additional cuts to seal corners and minimize gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If fixed-size boxes are used for packing products, then box management is simplified, but transportation efficiency deteriorates due to large gaps when product sizes vary
Solution Approach 1:
The box is designed with dynamic height adjustment capability through foldable side walls and adjustable bottom/cover sheets. The height can be changed by folding side walls along predetermined fold lines or adjusting the bottom/cover sheet height, allowing the box to adapt to different product heights while maintaining efficient space utilization during transportation
2Productivity
If height-adjustable box structures are implemented, then transportation efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The box is divided into multiple functional segments: side walls with fold lines for height adjustment, bottom sheet with adjustable height capability, cover sheet with corresponding adjustments, and reinforcement portions. Each segment can be independently manufactured and assembled, simplifying the overall manufacturing process while maintaining height adjustability
Solution Approach 2:
Fold lines are pre-formed on the side walls, bottom sheet, and cover sheet during manufacturing. These predetermined fold lines enable quick and easy height adjustment by the user without requiring complex tools or procedures, reducing the operational complexity despite the adjustable structure
3Adaptability or versatility
If foldable side walls are used to change box size, then box size can be adjusted to several kinds of sizes, but stepless adjustment is impossible leading to larger gaps
Solution Approach 1:
The bottom sheet and cover sheet are designed with adjustable height capability through fold lines and reinforcement portions. By folding the side walls along predetermined fold lines or adjusting the bottom/cover sheet height, the box can achieve continuous (stepless) height adjustment to precisely match product dimensions, minimizing gaps and improving transportation efficiency
Data Source
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AI summary
In order to assemble a box for sending products in which the height of the box is freely (steplessly) changed according to the size of each of the products, a base sheet (1) and a cover sheet (2) are supplied, the height of a product which is placed on a bottom sheet portion (11) of the base sheet (1) is measured, second fold lines (b) are formed on the base sheet (1) and the cover sheet (2) such that the second fold lines (b) are spaced from respective first fold lines (a) formed on the respective side portions of the a bottom sheet portion (11) and a top sheet portion (21), wherein the space between each of the first fold lines (a) and the corresponding one of the second fold lines (b) is adjusted based on the value of the measured height of the product, wherein the spaces between the respective first fold lines (a) and the second fold lines (b) of the base sheet (1) are side sheet portions (12) and the spaces between the respective first fold lines (a) and the second fold lines (b) of the cover sheet (2) are side sheet portions (22), wherein the spaces between the respective second fold lines (b) of the base sheet (1) and the edges of the base sheet (1) are folded sheet portions (13) and the spaces between the respective second fold lines (b) of the cover sheet (2) and the edges of the cover sheet (2) are folded sheet portions (23), each of the side sheet portions (12) and the folded sheet portions (13) of the base sheet (1) is folded in the same direction, the base sheet (1) and the cover sheet (2) are arranged so that the base sheet (1) crosses the cover sheet (2), the cover sheet (2) is placed on the base sheet (1) so that the top sheet portion (21) is placed on the folded sheet portions (13) of the base sheet (1), and each of the side sheet portions (22) and the folded sheet portions (23) of the cover sheet (2) is folded in the same direction to bond the folded sheet portions (23) of the cover sheet (23) to the bottom sheet (11).