Modular box assembly
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Solution Overview
Problem
Current packaging solutions for temperature-sensitive items are inefficient, as they often spoil, destabilize, freeze, or melt during storage or shipping due to temperature fluctuations, and are often bulky, specialized, and non-recyclable, leading to dissatisfaction and environmental issues.
Innovation Solution
A modular box assembly with insulated panels and a carrying accessory that maintains temperature through encapsulated insulation batts between sheets, secured by a border, and features a support bracket and handle system for versatility and ease of use, allowing for the transportation of hot, chilled, or frozen goods while being recyclable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulated packages are designed to maintain temperature during shipping, then temperature-sensitive contents are protected from spoilage and destabilization, but the packages become bulky and difficult to store
Solution Approach 1:
The insulated package is divided into a box and a separate insulation wrap that can be detached. The insulation wrap contains the insulation batt and can be removed or stored separately, allowing the box to be compact for storage while providing insulation when needed.
Solution Approach 2:
The insulation wrap is designed to be flexible and adaptable, allowing it to conform to the box dimensions and be easily stored when not in use. The support brackets enable dynamic configuration of the box structure to accommodate the insulation wrap.
2Reliability
If specialized insulated packages are created for hot, chilled, or frozen goods, then each temperature requirement is met, but shippers must maintain large stocks of specialized packaging
Solution Approach 1:
The insulation wrap can be used with boxes of different sizes and configurations, making a single insulation wrap design applicable to multiple box types. The support brackets are designed to accommodate various box dimensions, allowing one insulation wrap to serve multiple temperature control needs.
Solution Approach 2:
The insulation wrap design allows for adjustment of insulation thickness and configuration based on the specific temperature requirements. The same basic wrap structure can be adapted for hot, chilled, or frozen goods by modifying insulation parameters rather than creating entirely specialized packages.
3Reliability
If traditional insulated packages are used, then temperature maintenance is achieved, but the packages cannot be recycled and are disposed of in landfills
Solution Approach 1:
The package is segmented into recyclable components: the box, the insulation wrap, and the support brackets. Each component can be separately recycled or reused, with the insulation wrap being removable for separate processing.
Solution Approach 2:
The design enables recovery and reuse of the box and support brackets, while the insulation wrap can be recovered and potentially reused or recycled. This contrasts with traditional single-use insulated packages that are discarded entirely.
4Ease of operation
If support structures are added to the box, then versatility and ease of use are enhanced, but the device complexity increases
Solution Approach 1:
The support structure is divided into separate support brackets that can be independently attached to the box, rather than being an integrated complex structure. This modular approach simplifies assembly and reduces overall complexity.
Solution Approach 2:
The support brackets act as intermediaries between the box and the insulation wrap, providing a simple connection mechanism that enhances functionality without requiring complex integrated design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The modular box assembly effectively maintains desired temperatures during shipping, reduces waste by being recyclable, and enhances user convenience with its modular design and accessory features, addressing the inefficiencies of existing packaging solutions.
Implementation Method 1
an insulation wrap extending around the plurality of side panels... the insulation wrap comprising an insulation batt; a first sheet; and a second sheet, the insulation batt encapsulated between the first sheet and the second sheet
Implementation Method 2
the channel tab frictionally engaging the first sub-shoulder and the second sub-shoulder to secure the support bracket within the shoulder channel
Data Source
AI summary
A modular box assembly includes a box, a box cavity defined within the box, the box defining a top end and a bottom end, the top end defining a box opening to the box cavity, the box includes a side panel extending from the top end to the bottom end; a shoulder attached to the side panel, the shoulder extending inward from the side panel and into the box cavity, the shoulder comprising a first sub-shoulder and a second sub-shoulder, the first sub-shoulder, the second sub-shoulder, and the side panel defining a shoulder channel; and a support bracket comprising a channel tab and a support shelf, the channel tab positioned within the shoulder channel, the channel tab frictionally engaging the first sub-shoulder and the second sub-shoulder to secure the support bracket within the shoulder channel, the support shelf extending into the box cavity.