Modular box assembly
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Solution Overview
Problem
Packaging for temperature-sensitive contents faces challenges such as spoilage, destabilization, freezing, melting, or evaporation due to temperature extremes during storage or shipping, and existing insulated packages are often bulky, specialized, and non-recyclable, leading to inefficiencies and environmental issues.
Innovation Solution
A modular box assembly with insulated panels and liners that can maintain temperature extremes, featuring a box with laminated insulation batts and foldable designs for versatility and recyclability, allowing for the transportation of hot, chilled, or frozen goods while being compact and environmentally friendly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional insulated packages are used to maintain temperature extremes, then temperature stability is improved, but package bulk and storage difficulty worsen
Solution Approach 1:
The insulation system is divided into separate components: removable insulation panels and liner assemblies that can be detached and stored separately from the box structure. This allows the box to be compact when insulation is not needed, while providing full insulation capability when required.
Solution Approach 2:
The insulation configuration is made dynamic and adaptable through removable panels and foldable liners that can be adjusted or removed based on shipping requirements. This transforms the package from a static bulky structure to a dynamic system that adapts its insulation level and storage footprint.
2Temperature
If specialized insulated packages are used for different temperature applications (hot, chilled, frozen), then temperature-specific protection is improved, but device complexity and inventory requirements worsen
Solution Approach 1:
A single box design serves multiple temperature applications through interchangeable insulation panels and liner assemblies. The same box structure can be configured for hot, chilled, or frozen shipping by changing the insulation components, eliminating the need for separate specialized packages for each temperature range.
Solution Approach 2:
The insulation properties of the package are made changeable by swapping different insulation panels and liners with varying thermal characteristics. This allows the same physical package to adapt its thermal performance parameters to match different shipping temperature requirements.
3Temperature
If non-recyclable insulated packages are used, then insulation performance is improved, but environmental impact and waste generation worsen
Solution Approach 1:
The insulation panels and liner assemblies are designed to be recoverable and recyclable separate from the box structure. This allows the insulation materials to be recovered and processed appropriately at end-of-life, reducing landfill waste while maintaining insulation performance during use.
4Temperature
If bulky insulated packages are used, then temperature maintenance capability is improved, but storage efficiency and shipping cost worsen
Solution Approach 1:
By segmenting the insulation into removable panels and separate liners, the package achieves full insulation capability when assembled but compact storage when components are separated. This resolves the contradiction between maintaining temperature capability and storage efficiency.
Solution Approach 2:
The removable insulation panels and liners can be nested within or alongside the box structure when not in use, maximizing storage efficiency. The components are designed to fit compactly together, reducing the overall storage volume required while preserving full insulation capability when needed.
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, reduces waste by being recyclable, and enhances storage and shipping efficiency by accommodating various temperature-sensitive items in a single, adaptable package.
Implementation Method 1
the at least one insulated panel comprising at least one board and at least one insulation batt, the at least one board laminated to the at least one insulation batt, the at least one insulated panel configured to at least partially insulate the box cavity
Implementation Method 2
the at least one board laminated to the at least one insulation batt
Data Source
AI summary
A box assembly includes a box defining a box cavity within the box; and at least one insulated panel disposed within the box cavity, the at least one insulated panel including at least one board and at least one insulation batt, the at least one board laminated to the at least one insulation batt, the at least one insulated panel configured to at least partially insulate the box cavity.