Cardboard Tray With Hinged Pockets For Product Alignment
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Solution Overview
Problem
Existing packaging solutions, such as molded plastic inserts and cardboard or paperboard locating means, are not suitable for high-speed, high-volume machine erection and cannot effectively maintain product alignment for varying product sizes within a consolidated package, especially during shipping and user removal, and they are not environmentally friendly.
Innovation Solution
A tray made of lightweight foldable sheet material, such as cardboard or paperboard, with hingedly connected flaps that form pockets of varying depths, allowing for easy assembly and bonding to create a stable structure for product placement, which can be manufactured using a forming tool process with adhesive application for secure bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If molded plastic inserts are used to locate products, then product alignment is maintained, but environmental friendliness deteriorates and recyclability is reduced
Solution Approach 1:
The patent changes the material parameter from plastic to cardboard/paperboard, transforming the locating means into a recyclable, environmentally friendly material while maintaining the structural function of product alignment through engineered flap mechanisms and pocket formations
Solution Approach 2:
The patent employs single-use cardboard locating means that are inexpensive, recyclable, and designed for one-time use in packaging, replacing durable plastic inserts with disposable paper-based alternatives that align products effectively during shipping and are then discarded or recycled
2Object-affected harmful factors
If cardboard locating means are used, then environmental friendliness is improved, but suitability for high-speed machine erection deteriorates
Solution Approach 1:
The patent divides the locating means into separate modular components including individual pockets, flaps, and panels that can be independently formed and assembled, enabling high-speed automated machines to erect the structure efficiently through standardized, repeatable assembly operations
Solution Approach 2:
The patent incorporates pre-formed hinge lines, score lines, and adhesive application zones into the cardboard locating means before assembly, allowing automated machines to simply fold and bond pre-prepared components rather than forming complex shapes during the erection process, thereby increasing production speed
3Object-affected harmful factors
If integral cardboard locating means are used, then recyclability is improved, but adaptability to varying product sizes deteriorates
Solution Approach 1:
The patent employs flexible, foldable cardboard panels and flaps that can be dynamically configured into different pocket sizes and arrangements, allowing the same locating means structure to adapt to various product dimensions while maintaining recyclability through standardized cardboard material
Solution Approach 2:
The patent divides the locating means into modular, reconfigurable sections with adjustable flaps and pockets that can be configured to accommodate different product sizes and shapes, providing versatility while maintaining a standardized recyclable cardboard construction
4Strength
If plastic blister packs are used, then product protection is improved, but environmental friendliness and recyclability deteriorate
Solution Approach 1:
The patent changes the material parameter from plastic to cardboard/paperboard, maintaining protective functionality through engineered foldable structures, hinge lines, and pocket formations while achieving recyclability and environmental compatibility
Solution Approach 2:
The patent employs single-use cardboard packaging structures that provide adequate product protection during shipping and are then discarded or recycled, replacing durable plastic blister packs with inexpensive, environmentally friendly paper-based alternatives
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The tray provides a recyclable, environmentally friendly solution that maintains product alignment during shipping and user removal, suitable for high-speed packaging processes and accommodating products of different sizes within a single package, while reducing material usage and complexity.
Implementation Method 1
Within each pocket, at least one top sheet flap distal panel is adhesively secured to the bottom sheet flap distal panel
Data Source
AI summary
A tray made of cardboard, paperboard or other lightweight foldable sheet material that comprises one or more pockets (8) for receiving product. The tray comprises a top sheet defining one or more top sheet openings for the one or more pockets and a bottom sheet attached to the top sheet that comprises one or more bottom sheet openings that are aligned with the top sheet openings.