Pre-creased Corrugated Plastic Box Assembly
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Solution Overview
Problem
The transportation of food products, particularly fresh fish, in expanded polystyrene boxes is inefficient due to non-biodegradability, high transportation and storage costs, and labor-intensive assembly of corrugated plastic boxes which are not suitable for reuse.
Innovation Solution
A method for erecting pre-creased corrugated plastic sheet blanks into boxes using a multi-step folding and ultrasonic welding process, creating a strong, watertight, and recyclable packaging solution that reduces assembly time and improves box rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If boxes are made from expanded polystyrene, then thermal insulation properties are improved, but environmental sustainability deteriorates due to non-biodegradability
Solution Approach 1:
The patent transitions from expanded polystyrene material to corrugated plastic sheet material, changing the material parameters while maintaining the box structure. This allows the use of recyclable materials that can be sterilized and reused, addressing environmental sustainability concerns while preserving the insulating properties through appropriate material selection
Solution Approach 2:
The patent uses corrugated plastic sheet material which combines multiple layers including fluted structures and liners, creating a composite material that provides both thermal insulation and environmental sustainability through recyclability and reusability
2Object-affected harmful factors
If boxes are made from corrugated plastic sheet material, then environmental sustainability is improved, but assembly time increases due to laborious folding operations
Solution Approach 1:
The patent applies pre-creasing to the blank at specific locations before assembly. These pre-applied creases prepare the material in advance for folding, enabling rapid assembly by simply pressing the pre-creased areas rather than folding from scratch, thus reducing assembly time while maintaining environmental benefits
Solution Approach 2:
The blank is divided into multiple regions with different crease patterns (transverse creases, longitudinal creases, and creases extending from apexes). This segmentation allows different parts to be folded independently and simultaneously, streamlining the assembly process and reducing overall assembly time
3Strength
If multiple crease lines are added to the blank, then box rigidity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the blank into multiple functional regions (central region, side regions, corner regions) with specific crease patterns in each. This segmentation allows rigidity to be optimized in different areas independently, with transverse creases for one set of walls, longitudinal creases for another set, and apex creases for corner strength, while the modular design keeps manufacturing manageable
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 method significantly reduces the time and effort required to assemble boxes, enhances their strength and water-tightness, and addresses the environmental concerns by using recyclable materials, thereby improving the efficiency and sustainability of food product transportation.
Implementation Method 1
a method for erecting pre-creased planar blanks into boxes... using a multi-step folding and ultrasonic welding process
Data Source
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AI summary
A method for erecting a pre-creased planar blank (20) into a box (22) comprises: a first step of folding a blank (20) along selected crease lines; a second step of folding a first-stage partially folded box (26) along selected crease lines; a third step of securing a first outer longitudinal sidewall (ISW1) to a first inner longitudinal sidewall (1SW) and a second outer longitudinal sidewall (2SW1) to a second inner longitudinal sidewall (2SW); a fourth step of folding a second-stage partially folded box (28) along selected crease lines to form the fully erected box (22); and a fifth step of securing a first transverse flange (1TF) to first and second longitudinal flanges (ILF, 2LF), and a second transverse flange (2TF) to the first and second longitudinal flanges (ILF, 2LF). The blank (20) can be made of any suitable material, e.g., corrugated plastic sheet.