Cardboard Tray With Reinforcing Pillars For Display Versatility
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Solution Overview
Problem
Existing cardboard trays lack versatility for displaying and storing goods of various sizes, require complex assembly, and do not optimize space usage, while also being inefficient in production and environmental impact.
Innovation Solution
A modular cardboard tray design featuring a rectangular bottom and ring of side walls with reinforcing pillars formed by folding and gluing elements, allowing for easy assembly and disassembly, optimized space utilization, and high-throughput production, while being recyclable and reducing material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If corner pillars are obtained by folding end flaps, then good compression strength is achieved, but goods cannot be displayed on the sides
Solution Approach 1:
The side walls are divided into multiple segments: a base wall portion and an additional display wall portion that can be folded out. This segmentation allows the structure to maintain strength from the base while providing extended surfaces for displaying goods on the sides.
Solution Approach 2:
The side walls are designed with fold lines that allow them to change configuration dynamically. The display wall portions can be folded out to create displaying surfaces, or folded in to reduce profile, providing adaptability for different storage and display needs.
2Adaptability or versatility
If joining rods are used to connect trays, then modular connection is achieved, but the structure becomes complex
Solution Approach 1:
The connection functionality is merged into the tray structure itself through complementary geometric features on adjacent trays. The interlocking flaps and recesses eliminate the need for separate joining rods, achieving modular connection while reducing structural complexity.
Solution Approach 2:
The trays are designed with self-aligning and self-connecting features. When placed together, the complementary geometric features automatically guide the trays into proper alignment and secure the connection without requiring additional components or complex assembly procedures.
3Productivity
If multiple packing costs are reduced by modular trays, then storage efficiency improves, but production complexity increases
Solution Approach 1:
The tray components are pre-formed with integrated connection features and fold lines during the manufacturing process. This preliminary preparation allows for rapid assembly and modular stacking during storage and transport, improving productivity while keeping production complexity manageable through design integration.
4Productivity
If high-throughput production is achieved, then productivity increases, but manufacturing precision requirements increase
Solution Approach 1:
Different regions of the tray blank are designed with specific properties: reinforced areas at fold lines for precision, flexible areas for easy folding, and rigid areas for structural integrity. This local differentiation allows high-throughput production while maintaining necessary precision only where critical.
Data Source
AI summary
A tray made from cardboard sheet material comprising a rectangular bottom and a ring of side walls, i.e., two first opposing side walls, referred to as first walls, at least one of the first walls being connected on either side by first fold lines to end flaps referred to as first flaps, which may or may not themselves be connected respectively at the top part of same to a second flap by a second fold line, and two second opposing side walls, referred to as second walls. The second walls each comprise a rectangular central panel of which the length is less than the length of the bottom, the panel being connected, at each of the lateral ends of same, by a third fold line to a reinforcing member forming a pillar folded and glued to the central panel, and/or to the first flap of the adjacent first wall, i.e., a first reinforcing element located entirely separated from the adjacent first wall, and a second reinforcing element.