Rapid Assembling Container With Deltoidal Locking Sections
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Solution Overview
Problem
Existing paperboard or cardboard container assembly methods require significant effort, time, and materials, often necessitating fasteners, adhesive, and extensive training due to complex folding and assembly processes, which are inefficient and costly, especially for large-scale applications.
Innovation Solution
A container design featuring a bottom panel connected to a front panel and locking sections, with deltoidal sections and tabs/slots for rapid assembly, minimizing the need for adhesive and reducing assembly steps by using double folding joints and perforation scoring for easy folding and interlocking flaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fasteners and adhesive are used to assemble containers, then the container structure is secure and stable, but the assembly process requires significant time, effort, and materials
Solution Approach 1:
The patent replaces traditional mechanical fastening systems (screws, clips, adhesive) with a die-cut locking mechanism where tabs with locking features interlock with corresponding slots in adjacent panels. This mechanical interlocking system achieves secure assembly without requiring external fasteners or adhesive, thereby reducing assembly time and material usage while maintaining structural stability.
Solution Approach 2:
The container panels are designed with self-locking features where tabs automatically engage with slots when panels are folded together. The locking sections and tabs are pre-formed as integral parts of the panels, allowing the structure to assemble and secure itself without requiring external fasteners, adhesive application, or complex assembly tools, thus eliminating time-consuming assembly steps.
2Ease of manufacture
If complex folding and assembly steps are required, then the container can be assembled with basic materials, but significant effort and training are needed
Solution Approach 1:
The container is divided into modular panels, each with pre-formed locking sections, tabs, and slots. This segmentation allows each panel to be independently manufactured and then easily assembled with others through simple interlocking actions. The die-cut features are pre-formed during manufacturing, eliminating the need for complex field assembly or special tools, thereby reducing both manufacturing complexity and user effort.
Solution Approach 2:
The locking sections, tabs, and slots are pre-formed and die-cut during the panel manufacturing process rather than requiring formation during assembly. Score lines are pre-created to guide folding. This preliminary preparation of interlocking features and fold lines eliminates the need for complex assembly steps or special tools during container construction, making the process simple and requiring minimal training.
3Device complexity
If large portions of the blank are removed to assemble the container, then the container structure is simplified, but material waste increases
Solution Approach 1:
The locking sections, tabs, and reinforcement features are merged into integral parts of the container panels rather than being separate components. The tabs are formed as extensions of the panel structure itself, and the locking features are die-cut directly into the panel material. This integration eliminates the need to remove large portions of material for separate fasteners or reinforcement elements, reducing waste while maintaining structural simplicity.
Solution Approach 2:
The design minimizes material waste by carefully positioning die-cut tabs and locking sections to utilize the full blank material efficiency. The tabs are formed from existing panel material rather than requiring additional material or removal of large sections. The interlocking system is designed to achieve structural simplicity while preserving maximum usable material from the original blank.
Data Source
AI summary
A storage container includes a bottom panel that has a parallel front edge and rear edge, and a parallel first and second side edge. A front panel is connected to the bottom panel along the front edge and is further connected with a front locking section. A first side panel is connected to the first side edge of the bottom panel and is further connected to a first side locking section. A second side panel is connected to the second side edge of the bottom panel and is further connected to a second side locking section. A rear panel is connected to the rear edge of the bottom panel and is further connected to a rear locking section. The rear panel has four deltoidal sections. The container is configured for rapid assembly.