Molded Plastic Crayon Case with Integral Hinges
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Solution Overview
Problem
Traditional cardboard crayon boxes are not durable and break down easily, making them unsuitable for repeated use and storage of partially used crayons, which often get lost or difficult to organize.
Innovation Solution
A molded plastic crayon case with integral 'living' hinges and a unitary structure that transforms from a closed to an open configuration, providing a durable and organized storage solution for crayons, including features like assembly tabs, detents, and a hinged lid for secure closure and easy access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional cardboard crayon boxes are used, then they are easy to manufacture and inexpensive, but they lack durability and break down easily upon manipulation and exposure to liquids
Solution Approach 1:
The patent employs composite materials by combining a rigid outer shell made of durable plastic with an inner cardboard tray for crayon organization. This composite structure leverages the strength and water resistance of plastic while maintaining the manufacturing simplicity and cost-effectiveness of cardboard for the internal components, thereby resolving the contradiction between durability and ease of manufacture.
Solution Approach 2:
The crayon box is divided into distinct segments: a durable outer plastic shell and an inner cardboard tray. This segmentation allows each component to be optimized independently - the outer shell for strength and protection, and the inner tray for organization and cost-effective manufacturing - thus achieving both durability and ease of manufacture.
2Ease of operation
If crayons are stored in a catch-all container, then storage capacity is increased, but organization is lost and desired crayons become difficult to find
Solution Approach 1:
The inner cardboard tray is segmented into multiple compartments and slots that correspond to different crayon colors and sizes. This segmentation maintains organization by providing designated spaces for each crayon, making it easy to locate specific colors while still utilizing the increased storage capacity of the container.
Solution Approach 2:
Different sections of the inner tray are designed with specific local qualities - some areas have individual slots for single crayons, while other areas have larger compartments for groups of crayons. This localized organization optimizes accessibility for different usage scenarios while maintaining overall order.
3Reliability
If crayons are stored in a traditional box, then basic storage is provided, but the box does not protect crayons from breaking during transport
Solution Approach 1:
The segmented structure with the rigid outer shell and inner tray provides protection by creating a cushioning effect and preventing direct contact between crayons and the external environment. The segmentation allows the crayons to be held securely in place, reducing movement and breaking during transport without requiring overly complex structural elements.
Solution Approach 2:
The inner cardboard tray acts as a pre-designed cushioning element that absorbs shocks and prevents crayon breakage during transport. This beforehand cushioning is built into the structure, providing protection without adding complex active mechanisms.
4Reliability
If a hinged lid is added to the crayon case, then secure closure is achieved, but manufacturing complexity increases
Solution Approach 1:
The hinged lid is merged with the outer plastic shell as a single integrated component, molded as one piece. This combining of the lid and hinge into a single molded structure achieves secure closure functionality while avoiding the need for separate hinge components, thereby reducing manufacturing complexity despite the added functionality.
Solution Approach 2:
The hinged lid structure combines the rigidity of plastic for secure closure with flexible hinge regions that allow movement. This composite approach within a single molded part achieves both closure security and manufacturability by utilizing varying material densities and flexibilities in different zones of the same component.
Data Source
AI summary
A writing utensil container formed from a single plastic mold, including a container front panel, a front bottom component, a container back panel, a back bottom component, and a container lid component. A bottom integral hinge component may pivotally couple the back bottom component and the front bottom component, allowing the container front and back panels to pivot toward and away from each other. A lid integral hinge component may pivotally couple to the container back panel with the container lid component for opening and closing thereof. The container front and back panels may have coupling mechanisms that selectively engage with each other to prevent pivoting about the bottom integral hinge component to retain crayon boxes between the container front and back panels. A front closure feature of the front panel may selectively engage with a lid closure feature for selectively retaining the container lid component in a closed position.