Roller Box Assembly for Easier Mattress Transport
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Solution Overview
Problem
The difficulty in transporting and delivering mattresses due to their size and weight often requires customers to schedule deliveries, which can be inconvenient and costly, and existing solutions like compressed mattresses in boxes do not fully address the need for efficient retail-to-home transport.
Innovation Solution
A roller box assembly with fixed-axis wheels and a handle, allowing customers to roll compressed and bagged mattresses out of stores and into vehicles, utilizing a cardboard box structure with wheels along the bottom edge and a handle on top, ensuring stability and ease of movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a mattress is compressed and placed in a box, then the volume is reduced making it easier to transport, but the box becomes difficult to move due to weight and lack of mobility features
Solution Approach 1:
The box is equipped with wheels that enable it to transition from a static container to a dynamic, mobile unit. The wheels are positioned at the bottom corners of the box, allowing the compressed mattress box to be rolled easily across floors and into vehicles, directly addressing the mobility issue while maintaining the volume reduction benefit of compression.
Solution Approach 2:
A handle is attached to the top of the box serving as an intermediary component that facilitates easy grasping and rolling. This handle acts as a mediator between the user and the heavy box, enabling simple manipulation and transport of the compressed mattress without requiring lifting or carrying.
2Ease of operation
If wheels are added to the box to improve mobility, then transport ease is improved, but the device complexity increases
Solution Approach 1:
The mobility system is segmented into discrete, simple components: individual wheels attached at specific corners and a separate handle attached to the top. This segmentation allows each component to perform its specific function independently while keeping the overall structure relatively simple and easy to manufacture.
Solution Approach 2:
The box appears to be designed as a disposable or single-use packaging solution. The simplicity of the wheel and handle attachments, combined with the use of standard cardboard box materials, suggests a cost-effective, no-frills approach where the packaging serves its transport purpose and can be discarded afterward, reducing the need for complex, durable designs.
3Volume of moving object
If the mattress is rolled into a cylindrical shape, then it fits better in the box and reduces volume, but the rolled structure may unroll during transport creating instability
Solution Approach 1:
A cylindrical bag or wrapping is used as an intermediary layer between the rolled mattress and the box interior. This cylindrical enclosure maintains the compressed shape of the mattress roll, prevents unrolling during transport, and provides structural stability while allowing the mattress to fit efficiently within the box container.
Data Source
AI summary
A roller box assembly includes a roller box and a bedding product contained in the roller box. The roller box includes a cardboard box portion, a pair of fixed-axis wheels, and a handle. The fixed-axis wheels are disposed along a corner edge of a bottom portion of the box portion. The handle portion is attached to the top portion of the box portion. In one embodiment, the bedding product is a mattress that has been compressed and rolled into a cylinder shape. A retail customer can purchase the bedding product at a retail store, and can then transport the purchased product out of the store by pulling the box from the handle such that the box rolls on its rollers.