Integrated Collapsible Box with Built-in Dividers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current boxes for transporting rectangular electronic devices require three separate components: an exterior box, dividers, and cushioning, leading to inefficiency and loss of parts during storage and reassembly, especially in space-constrained environments like cable company local stores.
Innovation Solution
A single-piece box with integrated collapsible dividers and cushioning, made from a scored semi-rigid material that can be easily assembled and disassembled into a flat shape, allowing for secure transportation and storage of multiple rectangular products without losing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If three separate components (exterior box, dividers, cushioning) are used, then product protection is improved, but device complexity and storage difficulty increase
Solution Approach 1:
The patent combines the exterior box, dividers, and cushioning into a single integrated component made from one piece of corrugated fiberboard. The dividers are formed by folding and gluing sections of the same material as the box, and cushioning is provided by die-cutting recesses in the bottom of the box, eliminating the need for separate components while maintaining protection functions
Solution Approach 2:
The single-piece design makes the box multi-functional: it serves as the exterior container, contains integrated dividers for product separation, and incorporates cushioning elements, all in one component. This universal design eliminates the need for multiple specialized parts
2Reliability
If three separate components are used, then product protection is improved, but ease of operation deteriorates due to assembly and disassembly requirements
Solution Approach 1:
By merging all protective functions into one piece of fiberboard, the box requires no assembly or disassembly. The dividers and cushioning are permanently integrated through folding and gluing during manufacturing, eliminating operational steps for users
Solution Approach 2:
The box is pre-assembled during manufacturing with dividers and cushioning already in place. The preliminary action of assembling the box during production eliminates the need for end-users to perform assembly or disassembly operations
3Reliability
If three separate components are used, then product protection is improved, but loss of substance increases due to lost or damaged parts
Solution Approach 1:
The single-piece design eliminates separate components that could be lost or damaged independently. All protective elements are permanently integrated into one structure, so there are no loose parts to misplace or damage during storage and handling
Solution Approach 2:
The integrated design ensures that when the box is reused, all protective elements are recovered together as one unit. There is no risk of leaving dividers or cushioning behind, as they are permanently attached to the box structure
4Reliability
If fully assembled box is stored, then product protection is maintained, but area occupied increases
Solution Approach 1:
The box includes collapsible sides that can be folded inward to reduce the box from its expanded protective form to a compact flat form for storage. This dynamic transformation allows the box to adapt between providing maximum protection during use and occupying minimal space during storage
Data Source
AI summary
A specialized box with integrated dividers is suitable for transporting multiple rectangular products, such as set top boxes. The box is formed of a single sheet of material, scored in six panels so that a leading panel forms a partition around which the other panels are folded and secured, with the final panel partially overlapping the second panel to form a joined side of the box. An insert with two walls, formed of a single sheet of material, can be folded into a rectangular shape and inserted in the box to create walls between the partition and each parallel side of the box. Cushioning pads can be attached to bottom flaps of the box. When flat, multiple boxes can be compactly stored or transported on a pallet. When folded into a cube, the box holds up to four rectangular products in four separate, protected compartments within the box.