Packed Roof Window Box With Integrated Side-Wall Retention
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Solution Overview
Problem
Existing roof window products have a significant climate footprint due to excessive packaging materials and lack of recyclability, while maintaining secure and protected component handling during installation.
Innovation Solution
A packed roof window product design where a first component is carried by the side wall of the box, utilizing previously unused space to reduce box dimensions and eliminate auxiliary fastening means, thereby reducing material consumption and facilitating recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional packaging methods are used with adhesives and auxiliary fastening means, then component security is improved, but material consumption increases and recyclability deteriorates
Solution Approach 1:
The box structure is merged with the fastening function by integrating recesses and protrusions directly into the box walls. The first wall contains recesses that receive protrusions from the first component, while the second wall contains protrusions that engage with recesses in the second component. This integration eliminates the need for separate adhesives, tapes, or straps, reducing material consumption while maintaining component security during transportation.
Solution Approach 2:
The box serves multiple functions simultaneously: it provides containment for components, structural support during transportation, and integrated fastening through its wall recesses and protrusions. The side walls are designed with both structural integrity and fastening features, allowing the box to secure components without additional fastening materials, thereby improving recyclability while maintaining reliability.
2Loss of substance
If box size is reduced to minimize climate footprint, then material consumption is improved, but component protection and security deteriorate
Solution Approach 1:
The fastening solution transitions from using additional external materials to utilizing the vertical dimension of the box walls. Recesses and protrusions are positioned at different heights on the first and second walls, creating a three-dimensional interlocking system that secures components within a compact footprint. This dimensional approach allows effective fastening without increasing the overall box size, maintaining component protection while minimizing material consumption.
Solution Approach 2:
The component fastening features are nested within the box structure itself. The recesses in the first wall and protrusions in the second wall are integrated into the box wall thickness, allowing the fastening mechanism to occupy the same spatial envelope as the containment structure. This nesting eliminates the need for additional fastening materials that would increase box size, maintaining compact dimensions while ensuring component security.
3Reliability
If auxiliary fastening means such as adhesives and straps are used, then component security is improved, but recyclability deteriorates
Solution Approach 1:
The fastening function is extracted from separate auxiliary materials (adhesives, tapes, straps) and embedded directly into the box structure. The recesses and protrusions are molded or formed as integral parts of the box walls during manufacturing, eliminating the need for separate fastening materials. This extraction allows the entire box to be recycled as a single material stream without contamination from mixed materials, improving recyclability while maintaining component security through the integrated fastening features.
Data Source
AI summary
A packed roof window product wherein a plurality of diferently sized window product related components are packed in a box and one of the components is carried by a side wall of the box.