Cardboard Tray Segmentation for Compression Resistance
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Solution Overview
Problem
Existing single-blank corrugated cardboard trays lack sufficient compression resistance and are difficult to stack securely due to fragile tenons and horizontal corrugations, with geometry defects significantly impacting their vertical compression resistance.
Innovation Solution
A tray formed of three separate parts, including a bottom connected to two side walls with longitudinal flaps and transverse flaps, allowing for optimized basis weight and corrugation orientation to enhance vertical compression resistance and facilitate easy stacking, while being tolerant to geometric defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If single-blank corrugated cardboard trays are used, then manufacturing is simple, but vertical compression resistance is insufficient
Solution Approach 1:
The tray is divided into three separate parts: a bottom part and two side wall parts, each manufactured independently and then assembled. This segmentation allows each component to be optimized for its specific function while maintaining manufacturing efficiency through standardized production processes for each module.
Solution Approach 2:
The invention uses corrugated cardboard with specific basis weights and corrugation orientations for different parts. The side wall parts use material oriented to maximize vertical compression resistance, while the bottom part uses material optimized for its load-bearing function, creating a composite structure with superior overall performance.
2Ease of operation
If stacking tenons are added to enable secure stacking, then stacking capability improves, but the tenons are fragile and difficult to insert precisely
Solution Approach 1:
Instead of adding protruding tenons that extend outward and are prone to breakage, the invention uses recessed mortices that receive inserting elements. This inversion makes the receiving structure more robust while maintaining precise alignment capabilities through the interlocking geometry of the mortice-and-tenon joint.
3Ease of manufacture
If horizontal corrugations are used in side walls, then manufacturing is simple, but compression resistance is insufficient
Solution Approach 1:
The invention changes the corrugation orientation parameter from horizontal to vertical in the side wall parts. This parameter change aligns the corrugation direction with the primary load direction during stacking, maximizing compression resistance while maintaining the simplicity of corrugated cardboard manufacturing processes.
4Strength
If protruding elements and corner beams are added to increase vertical compression resistance, then compression strength improves, but the tray geometry becomes more complex and sensitive to defects
Solution Approach 1:
The invention applies different material properties and structural characteristics to different parts of the tray. The side wall parts use vertically corrugated material optimized for compression resistance, while the bottom part uses material optimized for its specific function. This local optimization achieves high overall strength without requiring complex global structural modifications.
Data Source
AI summary
The invention relates to a cardboard tray made of three parts, to an assembly of blanks, and to a device and method for producing such a tray. The tray comprises a first part defining a bottom connected by first fold lines to two first opposite sidewalls and two second parts defining second opposite sidewalls, each comprising at least one longitudinal first flap connected to said second wall by a second fold line and glued on the bottom, and two sets of transverse flaps, each comprising at least one transverse flap glued to a first corresponding opposite side wall, respectively.