Carton Corner Folding Structure for Strength and Material Reduction
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Solution Overview
Problem
Current carton designs face challenges in minimizing material usage while ensuring strength and security for transporting heavy loads, particularly in packaging multiple articles, and require improvements in machine handling characteristics.
Innovation Solution
A corner folding structure comprising multiple hinged panels with a severance line that bypasses the intersection of fold lines, allowing for efficient folding and secure closure, and optional gusset panels for enhanced stability and projection, facilitating the formation of a tubular structure that securely holds articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional carton designs use more material to ensure strength for heavy loads, then the strength and security of the carton is improved, but the material usage increases and wastage is generated
Solution Approach 1:
The carton is divided into multiple panels (front, back, side walls) that are hingedly connected, allowing each panel to be optimized independently for strength while minimizing overall material usage. The severance line segments the blank to create precise panel boundaries without excess material.
Solution Approach 2:
The corner folding structure adds a third dimension by creating folded corners that rise vertically from the base panels. This dimensional transformation allows the carton to gain structural strength and load-bearing capacity without adding more material, as the folded corners act as reinforced edges.
2Strength
If traditional carton designs use additional components like glue or staples to ensure secure closure, then the security and strength of the carton is improved, but the device complexity and manufacturing steps increase
Solution Approach 1:
The carton panels are designed with self-securing features where the folded corners and hinged connections automatically lock into place during assembly. The structure serves itself by using its own geometry and material properties to create secure closures without requiring external fasteners, adhesives, or complex assembly mechanisms.
3Ease of operation
If traditional carton designs use complex folding structures to improve machine handling, then the machine handling characteristics are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The corner folding structures are pre-configured in the blank with predetermined fold lines and severance lines that guide the folding process. This preliminary arrangement of folds and cuts ensures that during high-speed machine assembly, the panels automatically follow the correct folding path without requiring complex real-time adjustments or extremely tight tolerances.
Data Source
AI summary
Aspects of the disclosure relate to a carton for packaging one or more article and a blank for forming the carton. An aspect of the invention provides a corner folding arrangement comprising a first panel (18) having a corner defined by an end edge and a side edge. A second panel (32b) is hingedly connected to the end edge of the first panel along a first fold line. A third panel (20) hingedly connected to the side edge of the first panel along a second fold line. A fourth (34b) and fifth (36b) panel couple the second panel to the third panel. The fourth panel is hingedly connected to the second panel along a third fold line and the fifth panel is hingedly connected to the third panel along a fourth fold line. A severance line (70) extends between the first and fourth fold lines or between the second and third fold lines. In an unfolded blank form the severance line bypasses a notional intersection of the first and second fold lines such that the notional intersection is located on one side of the severance line spaced apart from the fourth and fifth panels.