Carton Corner Insert Structure for Compression-Resistant Packaging
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Solution Overview
Problem
Existing packages for flowable materials lack sufficient structural reinforcement, leading to issues such as compression, bending, and crushing, especially when stacked or transported, and often require additional reinforcement materials like corrugated outers.
Innovation Solution
A carton package design incorporating inserts with protrusions that enhance structural integrity by providing resistive forces against compressive forces, allowing for direct stacking without additional reinforcement and using lighter materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a separate insert is used to retain products in a carton, then product stability is improved, but device complexity increases and assembly time increases
Solution Approach 1:
The patent combines the insert and carton into a single integrated container structure. The partition walls are directly formed as part of the container walls, eliminating the need for separate inserts. This merging reduces package complexity while maintaining product stability through the integrated partition design.
Solution Approach 2:
The container structure serves multiple functions simultaneously: it provides product containment, structural support, and partitioning all in one element. The partition walls are formed integrally with the container walls, allowing the same structure to fulfill both containment and division functions, thereby reducing the number of components needed.
2Stability of the object's composition
If a separate insert is used to retain products in a carton, then product stability is improved, but manufacturing cost increases
Solution Approach 1:
The insert and carton are merged into a single molded structure, reducing the number of manufacturing steps. Instead of producing separate inserts and cartons and then assembling them, the integrated design allows for single-step molding, thereby reducing manufacturing cost and improving ease of production.
Solution Approach 2:
The container structure is designed to perform multiple functions (containment, partitioning, support) in a single component, which simplifies the manufacturing process. This multi-functionality reduces the number of parts that need to be manufactured and assembled, leading to lower production costs.
3Device complexity
If conventional cartons without inserts are used, then device complexity is reduced, but product stability deteriorates
Solution Approach 1:
The partitioning function traditionally provided by separate inserts is merged into the container wall structure itself. The partition walls are formed as integral parts of the container, maintaining product stability while avoiding the complexity of separate insert components.
4Loss of time
If conventional assembly methods are used, then assembly time increases, but manufacturing precision is reduced
Solution Approach 1:
By merging the insert and carton into a single integrated structure, the alignment and attachment steps are eliminated. The partition walls are formed directly as part of the container during molding, ensuring precise alignment without requiring separate assembly operations.
Data Source
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AI summary
A package for holding at least one product includes a carton and at least one insert. The carton includes a plurality of panels extending at least partially around an interior of the carton to form at least one comer of the carton. The at least one insert is at least partially disposed in the interior of the carton adjacent the at least one comer to reinforce the carton, and includes a first panel, a second panel, and an intermediate portion between the first panel and the second panel. Each of the first panel and the second panel is attached to a respective panel of the plurality of panels and the intermediate portion is free from attachment to the plurality of panels.