Reusable Box Blank Locking Mechanism
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Solution Overview
Problem
Existing box blanks face challenges in reusability due to insufficient strength under load and damage from interlocking structural features like dart-type locks, which are not well-suited for frequent reuse.
Innovation Solution
A reusable box blank design featuring a locking structure with an overlay panel, slot, flap, and tab, where the tab has a spine and wings that bend away from the coplanar position during insertion and resiliently return to secure the panels in orthogonal positions without adhesives, ensuring robust interlocking without damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesives are used to secure panels in box configuration, then the box structure is strongly secured, but the blank cannot be easily disassembled for reuse
Solution Approach 1:
The locking structure is divided into separate components: a locking panel with a locking feature and a counterpanel with a receiving feature. This segmentation allows the panels to be strongly locked together while maintaining the ability to disassemble by simply separating the components without damaging adhesives or the blank itself.
Solution Approach 2:
The locking feature acts as an intermediary mechanism between panels. It includes a locking member that engages with a receiving member, creating a reversible mechanical connection that provides strong securing during use but allows easy disassembly when needed, eliminating the need for permanent adhesives.
2Ease of operation
If interlocking structural features are used to improve reusability, then easy disassembly is achieved, but the interlocking features suffer from damage under strain
Solution Approach 1:
The locking feature utilizes elastic deformation as a key parameter. The locking member is designed to elastically deform during engagement and disengagement, allowing it to flex under strain without permanent damage. This elastic parameter change enables the interlocking feature to maintain durability while providing easy assembly and disassembly through controlled flexibility.
3Strength
If dart-type locks are used for interlocking, then panel securing is achieved, but the dart tab becomes permanently deformed after repeated insertion and removal
Solution Approach 1:
The locking member is designed with elastic properties that allow it to reversibly deform during engagement and disengagement. This elastic parameter change enables the locking feature to withstand repeated insertion and removal cycles without permanent deformation, significantly extending the blank's reuse duration compared to rigid dart-type locks.
Solution Approach 2:
The locking structure employs composite design elements combining rigid and flexible components. The locking member incorporates elastic material properties that allow it to flex under stress while maintaining structural integrity, preventing the permanent deformation that occurs with purely rigid dart-type locking mechanisms.
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 design allows for secure assembly and disassembly of the box without adhesives, maintaining structural integrity under load and enabling frequent reuse by minimizing damage to the blank's components.
Implementation Method 1
Each of the wings is configured to bend away from the bottom panel from a coplanar position with respect to the spine as the tab is being inserted in the slot. Each of the wings is further configured to resiliently return toward its respective coplanar position when the tab is received in the slot.
Data Source
AI summary
A blank for being repeatably assembled into a box configuration without the use of adhesives. The blank has a bottom panel, a side panel foldably attached to the bottom panel, an end panel foldably attached to the bottom panel, and a locking structure configured to secure the side panel and the end panel in respective orthogonal positions with respect to the bottom panel. The locking structure includes an overlay panel foldably attached to the end panel and foldable toward an overlying position in which it overlies a portion of the side panel. The locking structure also includes a slot in the bottom panel, a flap foldably attached to the bottom panel and extending into the slot, and a tab foldably attached to the overlay panel for being lockingly received in the slot to secure the overlay panel in the overlying position.