Reusable Cardboard Pack Folding for Stable Low-Waste Packaging
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Solution Overview
Problem
Existing packaging methods produce cartons with low inherent stability, require additional reinforcement, and generate significant waste due to complex cuts and separate inserts, complicating automated production.
Innovation Solution
A method for producing packaging from a single rectangular base blank with specific fold lines and dividing lines, allowing for the integration of inserts and ensuring stability without additional materials, enabling automated production with minimal waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If simple cartons without overlapping lid flaps are used, then the manufacturing process is simplified, but the inherent stability of the carton is low and additional reinforcement is required
Solution Approach 1:
The patent combines the stabilizing function with the lid flaps themselves by creating overlapping flaps that interlock to form a rigid structure. Instead of adding separate reinforcement elements, the lid flaps are designed to provide structural stability through their overlapping configuration, merging the closure function with the reinforcement function.
Solution Approach 2:
The patent pre-forms complex three-dimensional structures and reinforcement elements directly into the flat blank before folding. The blank includes pre-configured flaps, ribs, and interlocking features that are created through scoring and folding operations, eliminating the need for additional reinforcement steps during assembly.
2Adaptability or versatility
If complex cuts with multiple rectangles are used to create custom cartons, then the cartons can be adapted to item dimensions, but the proportion of waste material is high
Solution Approach 1:
The patent designs a universal blank format that can produce various carton sizes and configurations through different folding patterns. The standardized blank design with specific flap arrangements and score lines allows the same basic blank type to be used for multiple carton variations, reducing the need for custom-cut blanks for each size and thereby reducing waste.
Solution Approach 2:
The patent segments the blank into functional zones (base, sides, lid flaps, reinforcement elements) that can be independently configured through folding. This segmentation allows the blank to be optimized for material efficiency while still providing customization through the arrangement and dimensioning of these functional segments.
3Reliability
If separate inserts are used to hold items in packaging, then the item can be securely retained, but the coordination of material flow in automated production is complicated
Solution Approach 1:
The patent merges the insert function with the main packaging structure by forming retention features directly as integral parts of the folded blank. Internal flaps, ribs, and contoured surfaces are created from the same blank material, eliminating separate insert components and simplifying material flow in automated production while maintaining secure item retention.
Solution Approach 2:
The packaging structure is designed to self-form retention features during the folding process. The blank includes pre-configured elements that automatically create item-holding structures through folding and interlocking, eliminating the need for separate insert assembly steps and enabling automated production.
4Strength
If circumferential adhesive tape and cushioning material are added to simple cartons, then the safe transport of fragile items is ensured, but the device complexity and material usage increase
Solution Approach 1:
The patent combines the cushioning and protection functions with structural elements of the carton itself. Flaps, ribs, and interlocking features are designed to provide both structural strength and cushioning effects, eliminating or reducing the need for separate tape and cushioning material while maintaining protection for fragile items.
Solution Approach 2:
The patent pre-forms protective and cushioning features into the blank structure before assembly. Reinforcement ribs, cushioning flaps, and interlocking elements are created through scoring and folding operations on the blank, providing protection and strength without requiring additional materials or complex assembly steps.
Data Source
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AI summary
The invention relates to a method for producing a reusable pack from a cardboard material, in the case of which a main rectangular blank having sides X and Y and a total surface area xy is provided and 2 (a + h) ≤ x ≤ 3 (a + h) + a and y - 2 (h + r) ≤ b ≤ y, where a and b correspond to the side dimensions of the base surface area, h corresponds to the height and r corresponds to the width, or the width reduced by the height h, of the peripheral region R of the finished pack, and the method comprises the following further steps: - producing folding lines B in the main blank parallel to a first side Y at at least the following spacings from the latter: B1: a1 = h; B2: a2 = h + a; B3: a3 = 2h + a, wherein by virtue of at least two severing lines T being severed, each starting from opposite sides X, along at least one of the folding lines B, or the extension thereof, the spacing between those two end points ET of the severing lines T which are closer to an axis of symmetry S1, which is parallel to the side X, is selected such that the length of the spacing corresponds to a side B'' of the finished pack or the length of a side M of a pack insert.