Knockdown Display Container Assembly with Preassembled Shelves
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Solution Overview
Problem
The assembly of knockdown display containers is time-consuming due to the number of separate actions required, increasing fulfillment costs and time, which detracts from the utility provided by the display container in retail environments.
Innovation Solution
A method of manufacturing containers that uses a global shelf installation operation to assemble a plurality of shelves and a global divider installation operation to compartmentalize the container, reducing the number of touches required for final assembly by utilizing preassembled blanks with perforation and folding lines, allowing for easier and faster assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional separate assembly actions are used for knockdown containers, then assembly flexibility is maintained, but assembly time and labor costs increase
Solution Approach 1:
The patent combines multiple separate assembly actions into a single global shelf installation operation. Multiple shelves are installed simultaneously in one operation rather than individually, reducing the total number of touches required and significantly decreasing assembly time while maintaining flexibility through the knockdown design.
Solution Approach 2:
The container is manufactured as a knockdown preassembly with shelves and dividers pre-positioned in a collapsed state. This preliminary preparation allows the container to be quickly assembled by simply opening the sides and ends, eliminating the need for complex step-by-step assembly operations and reducing assembly time.
2Ease of operation
If multiple separate assembly operations are performed, then assembly precision can be controlled, but the number of touches and complexity increase
Solution Approach 1:
The patent merges multiple assembly operations into two simple global operations: global shelf installation and global divider installation. This consolidation reduces the number of touches from multiple separate actions to just these two operations, making assembly simpler while maintaining precision through the structured knockdown design.
Solution Approach 2:
The container is segmented into modular components (sides, ends, bottom wall, shelves, dividers) that can be independently manufactured and then assembled through simple opening and affixing actions. This segmentation allows for simple assembly operations while maintaining the structural integrity and precision of the final product.
3Productivity
If knockdown preassembly is used for shipping, then shipping efficiency improves, but assembly time increases
Solution Approach 1:
The container is preassembled in a collapsed knockdown state during manufacturing, with all components pre-positioned and secured. This preliminary action allows the container to be efficiently shipped in a compact form and then quickly assembled by simply opening the sides and ends, eliminating the need for complex assembly operations and reducing assembly time despite the knockdown configuration.
Data Source
AI summary
In accordance with the invention, a method of manufacturing containers such as shipping, display and display ready packaging, for example, and resulting containers and associated preassemblies and blanks are provided, which, when utilized, result in preassemblies that are more easily and quickly assembled into fully assembled containers. According to the invention, a primary flank is affixed to an auxiliary blank using adhesive applied to a second portion section of each of the plurality of divider sections included in the primary blank, such that, as the container is assembled, pressure on the auxiliary blank separates a first portion of each of the plurality of divider sections from second portion and carries each of the plurality of divider tabs to engage with corresponding lock slots of the first and/or second divider lock.