Basket Carrier Mitred Corners Nesting
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Solution Overview
Problem
Existing basket style carriers are not stackable, and their tertiary shipping cartons lack structural strength and aesthetic appeal, making them inefficient for transporting and displaying premium products, while also being resource-intensive in material usage.
Innovation Solution
The introduction of a package system featuring a secondary basket carrier with mitred corner structures that nest within a tertiary shipping carton, which is also designed with mitred corners, enhancing stackability and reducing material usage while maintaining structural integrity and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional basket style carriers are used, then they are easy to assemble and display premium products, but they are not stackable and require additional tertiary shipping cartons
Solution Approach 1:
The basket style carrier is designed with corner structures that nest within the corner structures of adjacent carriers, enabling stable stacking without requiring additional tertiary shipping cartons. The mitred corner panels create interlocking joints that provide structural stability when multiple carriers are stacked together.
2Reliability
If traditional tertiary shipping cartons are used, then they can transport basket carriers, but they lack structural strength and aesthetic appeal
Solution Approach 1:
The basket carrier corner structures are designed to nest within the corner structures of the tertiary shipping carton, creating a integrated system where the secondary and tertiary packaging work together. This nesting arrangement enhances the overall structural strength while maintaining transport capability.
Solution Approach 2:
The mitred corner structures create asymmetric geometric forms that interlock mechanically, providing enhanced structural strength compared to traditional rectangular corners. The angled panels distribute loads more effectively across the packaging structure.
3Ease of manufacture
If traditional packaging designs are used, then they are simple to manufacture, but they use excessive material and cause wastage
Solution Approach 1:
The packaging is segmented into modular corner structures that can be manufactured separately and assembled together. The mitred corner panels are cut from standard sheet materials in optimized patterns, reducing off-cut wastage while maintaining manufacturing simplicity through standardized cutting and folding operations.
Solution Approach 2:
The nesting design allows the basket carrier to fit tightly within the tertiary carton, eliminating the need for excessive void-fill material or oversized cartons. This tight integration reduces overall material usage while maintaining protective functionality.
4Reliability
If traditional packaging designs are used, then they are functional, but they lack aesthetic appeal for premium products
Solution Approach 1:
The mitred corner structures create visually appealing geometric forms with clean angled lines that convey a premium aesthetic. The asymmetric panel arrangements provide visual interest while maintaining structural functionality, enhancing the overall appearance of the packaged premium products.
Data Source
AI summary
The invention provide a package system comprising: at least one secondary packaging container (95) holding at least one primary container (‘B’); and a tertiary packaging carton (57; 157) holding the at least one secondary packaging container (95). The at least one secondary packaging container (95) is of the basket carrier style having an open-topped structure and comprises a base wall (78/80); opposed first and second side walls (14, 18); opposed first and second end walls (12, 16); and a medial handle structure (20/22) connected to the first and second end walls (12, 16) and disposed between the first and second side walls (14, 18). Additionally, at least one corner structure (14a) is disposed between the first side wall (14) and the first end wall (12) of the secondary packaging container (95). At least one corner structure (43a) is also disposed between the first side wall and the first end wall of the tertiary packaging carton.