Cardboard Tray Double-Folded Flange Rigidity
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Solution Overview
Problem
Current cardboard trays folded from unfolded sheets face issues with rigidity and stacking due to weak flanges that are prone to folding, making them unsuitable for top sealing and stacking, and the existing conical gluing systems struggle to connect these flanges effectively, leading to a loss of rigidity and unsuitable top edges for sealing.
Innovation Solution
The design incorporates double-folded first flange parts with second and third flange sections that create a flat circumferential flange without height differences, allowing for a top seal that maintains tension and enables stacking, while the third flange section secures the first flange part, preventing it from folding upwards and ensuring the top seal remains under tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional single-folded flanges are used in cardboard trays, then the manufacturing process is simple, but the flanges are weak and prone to folding, causing loss of rigidity and inability to stack
Solution Approach 1:
The flange is divided into multiple sections (first flange section, second flange section, third flange section) instead of being a single continuous structure. This segmentation allows each section to be independently folded and positioned, creating a multi-layered flange structure that significantly increases strength while maintaining manufacturability through standardized folding operations.
Solution Approach 2:
The flange structure transitions from a single-plane configuration to a multi-dimensional arrangement with sections folded at different angles and positions. The first flange section is folded horizontally, the second section is folded vertically against the wall, and the third section extends outward. This dimensional transformation creates a three-dimensional flange structure that resists folding and maintains rigidity.
2Reliability
If conventional flange structures are used, then the tray can be manufactured simply, but the top seal foil cannot maintain tension and the trays cannot be stacked
Solution Approach 1:
The flange sections are pre-configured with specific folding angles and positions during manufacturing. The first flange section is pre-folded horizontally, the second section is pre-folded vertically against the wall, and the third section is pre-positioned to extend outward. This preliminary configuration ensures that when the top seal foil is applied, the flange structure automatically maintains tension and enables stacking without requiring additional adjustment or complex assembly operations.
Solution Approach 2:
The multi-section flange structure is designed to self-maintain its configuration and tensioning force. The interlocking folds and geometric constraints of the three flange sections create a self-supporting structure that automatically maintains the top seal foil under tension during stacking, eliminating the need for external reinforcement or complex fastening mechanisms.
3Shape
If overlapping flange parts are used to connect walls, then the tray can be assembled, but the difference in thickness creates height differences that are unsuitable for top sealing
Solution Approach 1:
Instead of trying to reduce the thickness of the flange sections to achieve uniformity, the invention inverts the approach by adding structural layers. The multi-section design with vertical folding and overlapping configurations creates a compensated structure where the combined thickness of multiple thinner sections equals the thickness of a single thicker section, achieving uniform height without requiring precision control of individual section thicknesses.
Data Source
AI summary
A cardboard tray folded from an unfolded sheet of cardboard includes: a bottom wall with a circumferential edge formed out of an even number of straight edges; wall parts each arranged to a straight edge of the bottom wall; and first flange parts alternately arranged to subsequent wall parts along the circumferential edge. The first flange parts include at least a first, a second, and a third elongate flange part section, which are connected parallel and along an elongate edge to each other. The first elongate flange part section is arranged to the respective wall part, the third elongate flange part section is connected parallel and along an elongate edge to the second elongate flange part section, the third elongate flange part section is adhered to the outside of the respective wall part, and the second flange part section is double folded against the first flange part section.