Angled Lid Tabs for Corrugated Tray Material Reduction
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Solution Overview
Problem
Existing corrugated paperboard trays and cartons require more material to securely retain products, leading to higher costs and weight, while also being difficult to erect and use efficiently across various industries and geographies.
Innovation Solution
A corrugated paperboard tray design featuring a base with angled lid tabs that extend from corner to corner, allowing for secure product retention with reduced material usage, ease of assembly, and cost-effectiveness, utilizing a tray blank with specific fold lines and tear lines for easy erection and use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional corrugated paperboard tray designs are used to securely retain products, then product containment is achieved, but material usage increases leading to higher costs and weight
Solution Approach 1:
The lid is configured to extend at an angle from corner to corner of the base rather than covering the entire top surface. This angular extension creates a triangular overlap region that provides secure product containment through geometric constraint, reducing the overall lid area and thus material usage while maintaining reliability.
Solution Approach 2:
The lid tabs are positioned specifically at the corners of the base where products are most likely to shift or escape. By concentrating the containment function at these critical local points rather than uniformly across the entire lid, the design achieves reliable product retention with minimized material consumption.
2Reliability
If traditional tray designs are used, then product containment is secure, but the trays become difficult to erect and use efficiently
Solution Approach 1:
The lid is divided into discrete lid tabs that can be independently positioned and attached to the base walls. This segmentation allows for simplified assembly where each tab can be easily aligned and secured, reducing the complexity of erection compared to traditional single-piece lids while maintaining secure product containment.
3Reliability
If more material is used to securely retain products, then product containment improves, but costs and weight increase
Solution Approach 1:
By configuring the lid to extend at an angle from corner to corner, the design utilizes geometric efficiency to maximize containment effectiveness per unit area. This angular configuration reduces the total lid surface area required compared to a full coverage design, directly reducing material quantity and thus weight while maintaining adequate product containment.
Data Source
AI summary
The present application thus provides a tray for use with a number of products. The tray may include a base and a lid enclosing the base. The base may include a first wall and a second wall. The lid may include a first lid tab and a second lid tab such that the first lid tab of the lid is attached to an exterior of the first wall of the base and the second lid tab of the lid is attached to the exterior of the second wall of the base.