Cardboard Sheet with Interlocking Tongues for Compact Packaging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current packaging materials, such as cardboard with corrugated layers and expanded polystyrene, occupy large volumes during transport, leading to high costs and unsustainable energy consumption.
Innovation Solution
A sheet of cardboard designed for packaging that can be transported in a compact, two-dimensional form and transformed into a three-dimensional structure through the interlocking of tongues with grooves, providing necessary softness and protection for packaged goods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional packaging materials (corrugated cardboard, expanded polystyrene, thousand bubbles) are used to provide protection and softness, then the packaging performance is improved, but the transport volume increases significantly leading to high costs and unsustainable energy consumption
Solution Approach 1:
The packaging material is divided into multiple layers with distinct functions: a flat cardboard layer for structural support and three-dimensional elements with interlocking tongues for cushioning and impact absorption. This segmentation allows each layer to optimize its specific function while minimizing overall volume during transport.
Solution Approach 2:
The patent introduces three-dimensional elements with tongues that can be folded and interlocked to create vertical structure from a flat two-dimensional sheet. This dimensionality change enables the material to provide cushioning volume only when needed (during use), while maintaining compact flat form during transport.
2Object-affected harmful factors
If three-dimensional structures are added to cardboard to provide softness and impact cushioning, then the packaging performance is improved, but the transport volume and cost increase
Solution Approach 1:
The three-dimensional elements are designed to be dynamic rather than static - they can be folded flat for transport and then erected to provide cushioning during use. The interlocking tongues allow the structure to adapt its configuration based on whether it is in transport or packaging mode.
Solution Approach 2:
The patent changes the physical state and configuration parameters of the cardboard elements. During transport, the elements are in a flat, compressed state with minimal volume. During use, they are transformed into three-dimensional structures with increased volume and cushioning capability through folding and interlocking.
3Reliability
If multilayer cardboard structures are used to increase protection, then the packaging reliability is improved, but the manufacturing complexity and material consumption increase
Solution Approach 1:
The patent merges the functions of multiple separate packaging materials (flat cardboard for structure and three-dimensional elements for cushioning) into a single integrated sheet. The three-dimensional elements are attached directly to the flat cardboard layer, combining structural support and impact protection in one component.
Solution Approach 2:
The interlocking tongue structure serves multiple functions: it provides mechanical attachment between layers, creates three-dimensional cushioning volume, and enables easy assembly without additional fasteners. This multi-functionality reduces the need for separate components and simplifies the overall structure.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention concerns a sheet of cardboard (1) for packaging which includes elements (2) which, when installed, each create three-dimensional structures suitable for giving softness to said packaging material. This sheet allows it to be transported by occupying a relatively modest volume, and then becomes a cardboard having three-dimensional structures suitable for the packaging when it is used.