Reinforced Collapsible Box with Differential Panel Materials
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Solution Overview
Problem
Existing box designs often require heavier materials for the bottom panel to maintain stacking strength, leading to increased material costs and inefficient use of resources, as not all panels contribute equally to the structural strength.
Innovation Solution
A reinforced box design featuring a body board with a lightweight material for the bottom panel and heavier end panels made of different materials, attached via hinges and fold lines, allowing for optimized material distribution and reduced material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heavier material is used for the bottom panel to maintain stacking strength, then stacking strength is improved, but material cost increases
Solution Approach 1:
The patent applies different material weights to different panels of the box based on their specific structural requirements. The end panels use heavier material (e.g., 32-point test board) while the bottom panel uses lighter material (e.g., 23-point test board). This local differentiation ensures stacking strength is maintained where needed without unnecessarily increasing material usage in areas where it is not required.
Solution Approach 2:
The box is divided into separate panels (end panels and bottom panel) that can be manufactured independently with different material specifications. This segmentation allows each panel to be optimized for its specific function, with the end panels providing structural strength for stacking while the bottom panel provides sufficient support without excessive weight.
2Strength
If heavier material is used for all panels to ensure structural integrity, then stacking strength is improved, but material cost increases
Solution Approach 1:
The patent implements local quality by assigning different material weights to different panels based on their specific structural requirements. The end panels, which bear the primary stacking load, use heavier material (e.g., 32-point test board), while the bottom panel uses lighter material (e.g., 23-point test board). This targeted approach maintains overall structural integrity without the need to over-engineer all panels with heavy material.
3Ease of manufacture
If uniform material is used for all panels, then manufacturing simplicity is improved, but material cost increases due to inefficient distribution
Solution Approach 1:
The patent segments the box into separately manufacturable panels with different material specifications. The end panels are manufactured with heavier material for structural strength, while the bottom panel is manufactured with lighter material. This segmentation enables efficient material distribution while maintaining manufacturing feasibility through standardized panel production and assembly processes.
Data Source
AI summary
A reinforced box includes a body board including a first material, the body board including a bottom panel defining a first bottom side and a second bottom side, the first bottom side positioned opposite from the second bottom side; a first side panel hingedly attached to the first bottom side of the bottom panel; and a second side panel hingedly attached to the second bottom side of the bottom panel; and an end panel including a second material, the second material being different from the first material, the end panel attached to the first side panel and the second side panel.