Modular Container Walls with Interlocking Flanges
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Solution Overview
Problem
The rapid growth of e-commerce has led to increased packaging waste, as corrugated boxes used for shipping are often discarded after a single use, resulting in significant energy consumption for recycling and limited reuse potential.
Innovation Solution
Modular container systems composed of attachable walls with repeatable patterns and locking mechanisms, allowing for customizable dimensions and rotation, enabling reusable containers that can be assembled and disassembled for efficient shipping and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If corrugated boxes are used for shipping, then packaging is provided for goods transport, but packaging waste increases and recycling energy consumption rises
Solution Approach 1:
The container is divided into multiple detachable wall panels that can be separated and stored individually. Each wall panel is a self-contained unit with integrated joining mechanisms, allowing the container to be disassembled into manageable segments for compact storage and repeated use, thereby reducing packaging waste.
Solution Approach 2:
The container transitions from a static disposable box to a dynamic reusable system. The walls can be joined and detached multiple times, and the container can be reconfigured between different storage and transport states, enabling repeated use cycles that eliminate the need for continuous production of new packaging.
2Productivity
If disposable corrugated boxes are used, then shipping is enabled, but resource consumption and carbon footprint increase
Solution Approach 1:
Instead of discarding the container after single use, the system recovers the container for repeated use. The durable wall panels are designed to withstand multiple assembly-disassembly cycles, and the joining mechanisms are engineered for repeated engagement and disengagement, thereby recovering the packaging resource and eliminating recycling energy consumption.
3Adaptability or versatility
If modular attachable walls are used, then container dimensions can be customized, but device complexity increases
Solution Approach 1:
All wall panels are designed with standardized joining mechanisms that can connect to any other compatible wall panel. The same joining features serve multiple functions: structural connection, alignment guidance, and secure locking. This universality allows dimensional customization through simple selection of wall panel configurations rather than complex assembly procedures.
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
This solution reduces packaging waste, lowers shipping costs, and minimizes carbon footprint by enabling the reuse of containers, while providing adaptable dimensions for various shipping needs.
Implementation Method 1
a flexible finger extending outward of the base surface of the first side... a receptacle formed between the resilient first flange and the flexible finger. The receptacle is configured to receive a pin and hold the pin at the receptacle such that, when the pin is inserted into the receptacle, the flexible finger is prevented from flexing toward the resilient first flange.
Data Source
AI summary
A system of attachable walls includes first and second walls. Each such wall includes a first side having a base surface and a repeatable pattern. The repeatable pattern includes first, second, third, and fourth lateral segments. The second lateral segment includes a resilient first flange extending outward and a flexible finger extending outward. The flexible finger has a first side facing the resilient first flange, a second side, opposite the first, facing away from the resilient first flange and toward the first lateral segment, a first mating component positioned on the second side of the flexible finger, and a receptacle formed between the resilient first flange and the flexible finger. The fourth lateral segment includes a second flange extending away from the base surface of the first side. The second flange includes a second mating component positioned on a side of the second flange facing the third lateral segment.