Single-Piece Folding Box Structure to Prevent Collapse
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Solution Overview
Problem
Existing folding boxes are made from multiple parts, requiring manual assembly, leading to high costs, long production times, and potential joint failure, and may unintentionally collapse during use, while also occupying significant space in the collapsed state.
Innovation Solution
A folding box designed as a single coherent polymer unit with integrated hinges and engagement elements, allowing transformation between states without manual assembly, enhanced structural stability, and reduced risk of collapse, featuring a compact collapsed form.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If folding boxes are made from multiple parts requiring manual assembly, then flexibility and adjustability are improved, but production cost and time increase, and joint reliability decreases
Solution Approach 1:
The patent merges multiple separate parts (side sections, bottom sections, and hinges) into a single coherent polymer unit manufactured by injection moulding. This eliminates manual assembly requirements, reduces production time, and removes joint failure risks while maintaining the folding box's functional flexibility through integrated hinge mechanisms
2Ease of manufacture
If folding boxes are made from multiple parts with joints, then ease of manufacture is improved, but reliability decreases due to joint breaking risk
Solution Approach 1:
The patent combines all components into one monolithic polymer structure manufactured in a single injection moulding process. This eliminates separate joints and assembly steps, simultaneously improving ease of manufacture through automated production and reliability by removing weak joint interfaces that could fail during use
3Stability of the object's composition
If separate bottom inserts are added to prevent collapse, then stability is improved, but device complexity and space occupation increase
Solution Approach 1:
The patent integrates reinforcement features directly into the bottom sections of the single-piece polymer unit during injection moulding. This provides the necessary structural stability to prevent unintentional collapse during use while avoiding the added complexity and space occupation that would result from separate bottom inserts
Solution Approach 2:
The patent implements localized reinforcement features at specific areas of the bottom sections where structural support is most needed. This provides targeted stability to prevent collapse while minimizing overall material usage and structural complexity compared to uniform reinforcement approaches
4Stability of the object's composition
If engagement elements are added to bottom sections, then stability is improved, but device complexity increases
Solution Approach 1:
The patent integrates engagement elements directly into the bottom sections as part of the single-piece polymer unit manufactured by injection moulding. This provides the necessary stability to prevent unintentional collapse while avoiding the added complexity of separate engagement mechanisms that would require additional assembly steps
Data Source
Figure 1a~1b
Figure 2~3
Figure 4~5
AI summary
A folding box (1) comprising four side sections (2) interconnected by hinges and at least two bottom sections (3) is disclosed. The folding box can be transformed from a collapsed state, where the side sections extend substantially in parallel to the bottom sections, and a use state, where the bottom sections extend in a bottom plane and the side sections extend in a height direction away. Each bottom section is connected to at least one side section by at least one hinge (63), and each comprises an engagement element (34a) for engagement with another bottom section. All side sections (2), bottom sections (3) and hinges (61, 62, 63) form part of one box body being a coherent polymer unit, and each of the four side sections are permanently connected to two other side section. The set of folding boxes and a method of making a folding box are also disclosed.