Hexagonal Packaging with Non-Rectangular Flaps for Honeycomb Density
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Solution Overview
Problem
Current hexagonal packaging solutions do not fully optimize the reduction of packaging material and glue usage, and they leave dead spaces in pallet configurations, which can be improved to enhance packing density and shipping efficiency.
Innovation Solution
The design of an improved hexagonal box with non-rectangular end-flaps that minimize overlap and material usage, combined with a pallet configuration that arranges hexagonal boxes in a honeycomb pattern with trapezoidal and triangular spaces filled by trapezoidal boxes, maximizing packing density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional hexagonal boxes with rectangular end-flaps are used, then the boxes can be easily manufactured, but the amount of packaging material and glue used is excessive
Solution Approach 1:
The patent applies asymmetry by replacing traditional rectangular end-flaps with non-rectangular end-flaps that have irregular shapes. These non-rectangular flaps are designed to minimize overlap areas when forming the hexagonal box, thereby reducing the total amount of packaging material and glue required while maintaining structural integrity
Solution Approach 2:
The patent applies local quality by optimizing the shape and size of end-flaps at specific locations. Each end-flap is designed with a custom non-rectangular geometry tailored to its position on the hexagonal box, minimizing material usage at each local area while ensuring proper assembly and structural strength where needed
2Productivity
If hexagonal boxes are arranged in traditional pallet configurations, then loading is simple, but dead spaces remain unused reducing packing density
Solution Approach 1:
The patent applies segmentation by dividing the pallet loading space into distinct zones: a central honeycomb structure formed by hexagonal boxes, and peripheral trapezoidal spaces. Trapezoidal boxes are used to fill the trapezoidal spaces, effectively segmenting and utilizing all available space on the pallet without compromising loading efficiency
Solution Approach 2:
The patent applies dimensionality change by transitioning from a simple hexagonal arrangement to a composite honeycomb-trapezoidal configuration. This adds another dimensional aspect to the packing arrangement by incorporating trapezoidal boxes that fit into the peripheral spaces, thereby maximizing three-dimensional space utilization on the pallet
Data Source
AI summary
A hexagonal box is formed from a box blank having a rectangular main body divided into six sections which are separated by score lines so that the main body can be folded to create the hexagonal box. The main body has a set of six flaps extending from one end of the six sections, and a second set of six independent flaps extending from the other end of the six sections. Preferably, at least two-thirds of the end-flaps are non-rectangular. Once the box blank is folded into a hexagonal box, the end-flaps may folded inward to create closed ends with minimal end-flap overlap. The hexagonal boxes may be constructed to have handles. A plurality of boxes may be grouped together into a honeycomb formation to maximize the packing density for shipment or transport.