Self-assembling Box with Protruding Dividers for Bottle Separation
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Solution Overview
Problem
Self-assembling boxes for containing bottles in a lying-down position face issues with dividers encountering resistance and potential breakage, leading to incorrect separation and increased probability of bottle breakage, and side walls failing under elevated loads.
Innovation Solution
A self-assembling box design featuring protruding elements with a step profile that form dividers to separate bottles and a separator with complementary openings, supported by side walls and a lid, allowing for stable separation and weight distribution, and a method for assembly involving lateral compression to vertically position dividers and secure the bottom.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vertical dividers are arranged between bottles in a lying-down position, then bottle separation is achieved, but the dividers encounter resistance and may break or bend
Solution Approach 1:
The divider is designed to extend vertically from the bottom of the box upward, creating a three-dimensional structure that spans multiple levels. This vertical extension allows the divider to engage with bottles at different heights, providing separation without direct horizontal contact that would cause breakage. The divider's profile includes a base portion at the bottom and an upper portion extending upward, effectively using vertical space to achieve bottle separation while avoiding the horizontal resistance problem.
2Ease of manufacture
If side walls are designed to withstand only weight forces, then manufacturing cost is reduced, but the boxes are subject to breakages and rupturing under elevated loads
Solution Approach 1:
The side walls are segmented into multiple horizontal reinforcement elements that create a stepped or ribbed structure. These segmentation lines divide the side wall into multiple zones, with each zone providing localized structural support. The segmentation allows the side walls to better distribute and withstand elevated loads while maintaining a relatively simple manufacturing process, as the reinforcements can be added through standard forming techniques during box production.
3Manufacturing precision
If dividers are positioned to separate bottles, then correct bottle arrangement is achieved, but the dividers are more prone to breakage during box movement
Solution Approach 1:
The divider is designed with a rounded or tapered upper portion that gradually tapers toward the bottles, creating a cushioning effect. This geometric feature allows the divider to gently engage with the bottles without creating sharp edges or points that would concentrate stress and cause breakage during movement. The rounded profile provides a smooth transition that protects both the divider and the bottles from damage while maintaining correct bottle arrangement.
Data Source
Figure 1a
Figure 1b
Figure 2a
AI summary
Self-assembling box (1) for containing at least six bottles arranged on at least two superimposed rows in a lying-down position. Said box (1) comprises: - four side walls (11, 12, 13, 14) joined to four lower flaps (21, 22, 23, 24), respectively, each by means of a lower folding segment (51, 52, 53, 54), wherein said four flaps are engageable therebetween to form a bottom (2); - at least one upper flap (32) joined to a second side wall (12) by means of at least one upper folding segment (112), wherein said at least one upper flap (32) forms a lid (3); - a separator (4) suitable for horizontally separating two superimposed rows of bottles, wherein separator (4) has two openings (40',40''). The box (1) comprises two protruding element (61, 62) joined to a first lower flap (21) and to a second lower flap (22), respectively, each by means of a first bottom folding segment (101) and a second bottom folding segment (102) so that when assembling the box (1) they form two dividers (5, 6). Said two dividers (5, 6) are as high as the four side walls (21, 22, 23, 24) in such a way as to provide a support for the lid (3) in extending themselves towards the opening (40', 40").