Cardboard Multi-Layer Packaging With Self-Engaging Tabs
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Solution Overview
Problem
Conventional packaging structures for components require significant labor and time for assembly, often compromising protection when simplified for improved workability, and vice versa.
Innovation Solution
A packaging structure comprising a lower layer tray and a middle layer tray, both made of cardboard, with engaging tabs that facilitate easy assembly and enhance protection by securely holding components, including a motor with a decelerator, using a three-dimensional configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional vertical partition structure with multiple corrugated cardboard plates is used, then protection for components is improved, but labor and time required for packaging work increases
Solution Approach 1:
The packaging structure is divided into multiple layers (lower layer tray, middle layer tray, upper layer tray) with each layer providing protection. The engagement tabs segment the assembly process into simple insertion steps rather than requiring complex engagement of multiple corrugated plates
Solution Approach 2:
The engagement tabs are designed to automatically engage with the openings in the underlying layer when the tray is placed, eliminating the need for manual engagement operations. The structure serves itself by utilizing gravity and the geometric design of tabs and openings to achieve secure connection without additional labor
2Reliability
If conventional rectangular tube structure is used, then protection for components is improved, but workability deteriorates due to complex insertion operations
Solution Approach 1:
Instead of inserting protective elements into the component or complex tube structures, the invention inverts the approach by having the tray layers rest upon engagement tabs that protrude from the underlying layer. This reverses the insertion direction and simplifies the assembly operation
Solution Approach 2:
The engagement tabs automatically engage with the tray openings through simple placement, eliminating the need for manual insertion operations into slit-shaped gaps. The structure self-assembles by utilizing the geometric relationship between tabs and openings
3Ease of manufacture
If the protection structure is simplified to improve workability, then packaging work becomes easier, but protection for components deteriorates
Solution Approach 1:
The invention transitions from two-dimensional protective structures (flat partitions or single-layer packaging) to a three-dimensional multi-layer tray system. This adds vertical dimension with multiple layers (lower, middle, upper) that provide enhanced protection while maintaining simple horizontal assembly operations
Solution Approach 2:
The packaging structure uses composite construction combining cardboard trays with engagement tabs made from the same or similar material. This composite approach creates a unified structure that provides both protection and ease of assembly without requiring complex multi-material integration
Data Source
AI summary
A packaging structure disclosed herein includes a box in which a component is accommodated and a lower layer tray and a middle layer tray formed of a cardboard sheet. The lower layer tray is provided inside the box. The middle layer tray is provided above the lower layer tray inside the box. The lower layer tray includes a lower layer opening into which the component is inserted and fixed, and a lower layer first tab provided at an edge of the lower layer opening and folded downward. The middle layer tray includes a middle layer opening into which the component is inserted and fixed, and a middle layer first tab provided at an edge of the middle layer opening, folded downward, and engaged with the lower layer opening in a state of overlapping the lower layer first tab.