Auto-erecting Octagonal Carton from Single Paperboard Blank
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Solution Overview
Problem
Conventional 'bag in a box' dispensers for liquids are often difficult to construct and lack aesthetic appeal, typically requiring multiple pieces of material.
Innovation Solution
A carton designed from a single blank of paperboard material with an auto-erecting bottom, forming an octagonal shape, which can be easily assembled and scaled to accommodate varying bag sizes, using eco-friendly and FDA-compliant materials with soy-based inks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple pieces of material are used to construct the carton, then the structural strength and stability are improved, but the device complexity and ease of manufacture deteriorate
Solution Approach 1:
The patent merges multiple separate structural components into a single integrated blank. The bottom structure combines multiple flaps (first bottom flap, second bottom flap, third bottom flap, fourth bottom flap) and folding assemblies into one continuous piece of paperboard that forms the complete carton body when folded, eliminating the need to assemble multiple separate pieces.
Solution Approach 2:
The single blank is segmented into multiple functional zones with fold lines that create distinct panels and flaps. The bottom portion is divided into four separate flaps that can fold independently to form the auto-erecting bottom structure, allowing complex 3D formation from a flat 2D blank.
2Stability of the object's composition
If multiple pieces of material are used to construct the carton, then the structural stability is improved, but the ease of manufacture and assembly deteriorate
Solution Approach 1:
The patent combines multiple structural elements into one integrated blank that maintains structural stability through its folded configuration. The auto-erecting bottom structure achieves stability through the interlocking arrangement of four flaps and folding assemblies that work together when the blank is folded into the final carton shape.
Solution Approach 2:
The blank is pre-configured with fold lines, crease lines, and flap arrangements during manufacturing that enable automatic erection of the bottom structure. The geometry and positioning of the flaps are predetermined so that simple folding actions automatically create the stable 3D structure without requiring complex assembly operations.
3Ease of manufacture
If a simple single-piece design is used, then the ease of manufacture is improved, but the aesthetic appeal and uniqueness deteriorate
Solution Approach 1:
The patent employs asymmetric design elements in the blank configuration, including non-uniform flap sizes, varied fold line positions, and an octagonal overall shape. The bottom flaps are arranged asymmetrically with different dimensions and orientations, creating visual interest and uniqueness while maintaining manufacturability from a single blank.
Solution Approach 2:
The patent transforms a simple 2D flat blank into a complex 3D structure with octagonal geometry and auto-erecting bottom. The folding process introduces vertical dimension and spatial complexity, creating an aesthetically pleasing three-dimensional form from a relatively simple two-dimensional starting material.
Data Source
AI summary
The present invention provides a carton constructed from a single blank of paperboard material featuring an auto-erecting bottom. The carton includes first through eighth sides panels, a glue flap attached along a fold line to a first side edge of the first side panel, a first bottom flap attached along a fold line to a bottom edge of the second side panel, and a second bottom flap attached along a fold line to a bottom edge of the sixth side panel.The carton includes a first bottom folding assembly attached to a bottom edge of the third and fourth side panels, a second bottom folding assembly attached to a bottom edge of the seventh and eighth side panels, a third bottom folding assembly attached to the first side panel, and a fourth bottom folding assembly attached to the fifth side panel.