Corrugated Box Centering Tab and Perforated Recess Locking
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Solution Overview
Problem
Existing corrugated cardboard boxes used for stacking on pallets tend to slide during handling, and existing solutions for centering and locking are either fragile or inefficient, leading to weight and structural issues.
Innovation Solution
A corrugated cardboard box design featuring a polygonal section with lateral walls, an upper wall connected by first fold lines, and a lower wall with a centering tab and perforated recess that aligns and locks vertically, preventing sliding and damage during transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lateral tenons with orifices are used for centering boxes, then boxes are prevented from sliding, but the centering system becomes fragile and cannot withstand repeated handling
Solution Approach 1:
The patent replaces fragile permanent centering means (tenons with orifices) with a disposable cardboard insert that absorbs impact during handling. The insert is designed to be replaced after use, protecting the box structure while providing reliable centering for each stacking operation.
Solution Approach 2:
The cardboard insert acts as an intermediary element between boxes during stacking. It provides the centering function temporarily during handling operations, then can be removed or replaced, whereas the box structure itself remains intact for repeated use.
2Reliability
If flaps and overlaps are added to upper and lower walls for engagement, then lateral locking is achieved, but weight increases and perfect vertical stacking is prevented due to offsetting
Solution Approach 1:
The patent extracts the locking function from the box walls themselves and transfers it to a separate cardboard insert containing flaps and overlaps. This allows the box structure to remain lightweight while still achieving lateral locking through the insert's engagement features.
Solution Approach 2:
The locking mechanism is segmented into a separate component (cardboard insert) rather than being integrated into the box walls. This segmentation allows the insert to provide the necessary weight for stable engagement without adding permanent weight to the box structure.
3Reliability
If folding locking elements with tips are used, then engagement with notches is achieved, but sliding is not efficiently prevented due to play between tip and notch
Solution Approach 1:
The patent transitions from point-contact locking (tip-notch) to surface-contact locking through flaps with overlaps that engage in multiple dimensions. The flaps provide both vertical engagement and lateral constraint, eliminating the play present in tip-notch systems.
Solution Approach 2:
The patent combines centering and locking functions into a single integrated cardboard insert rather than using separate elements. The flaps and overlaps work together to simultaneously achieve precise centering and prevent sliding in multiple directions.
4Strength
If bonding of centering means is used, then strong attachment is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The cardboard insert is designed to be self-contained and self-securing through its folded flaps and overlapping structure. It requires no external bonding agents or complex attachment mechanisms, allowing for simple automatic formation while achieving strong attachment through its own structural features.
Data Source
AI summary
The present invention relates to a box, a blank, a set of blanks made from corrugated cardboard sheet and a method for forming a box having a polygonal section. The box has at least one centring tab (7) straddling at least one folding line (4) on its upper wall (2), cut out on its lateral sides (8), connected on one side to the upper wall (2) by a first joining line (10) and on the other side to the adjacent side wall (5) by a second joining line (6), a parallel and offset intermediate folding line (14) being provided such that the tab (7) forms a projecting portion (16) on account of the folding. The bottom comprises at least one perforated surface portion (18) which has a shape complementary to that of the tab such that the lateral edges of the recess are designed to cooperate in contact with the lateral edges of said tab, and is designed to fit into the projecting portion of a box from below.