Carton End Closure Flap with Web Panel Hinge
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Solution Overview
Problem
Existing carton designs struggle to efficiently use materials while ensuring the secure retention and transportation of articles, particularly in terms of strength and environmental considerations.
Innovation Solution
The carton design features a tubular structure with a top wall and side walls, incorporating an end closure structure with a top end closure flap, side end closure flaps, and web panels that are hingedly connected, allowing for secure closure and forming a carrying handle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the carton uses a simple open structure for easy formation, then manufacturing ease is improved, but the retention strength of articles deteriorates
Solution Approach 1:
The end closure structure is divided into multiple flaps (top end closure flap, side end closure flaps) connected by web panels with hinge lines. This segmentation allows the structure to be formed from a flat blank through folding while creating a secure multi-point closure system that retains articles strongly.
Solution Approach 2:
The hinge lines in the web panels enable dynamic movement during formation and use. The flaps can be folded into position and secured, allowing the carton to transition from a flat manufacturing state to a three-dimensional closed state, providing both ease of manufacture and strong retention.
2Strength
If the carton uses more material to strengthen the structure, then the strength and retention capability are improved, but material efficiency and environmental considerations deteriorate
Solution Approach 1:
Material is concentrated strategically at critical locations where strength is needed - specifically in the web panels connecting the flaps and at the hinge lines. The rest of the carton structure uses minimal material, optimizing the balance between structural strength and material efficiency.
Solution Approach 2:
The end closure structure combines multiple layers and components (flaps, web panels, hinge lines) to create a composite closure system that achieves high retention strength without requiring excessive material, as each component contributes specific structural functionality.
3Strength
If the end closure structure is made complex to secure articles firmly, then retention strength is improved, but device complexity and manufacturing difficulty worsen
Solution Approach 1:
The closure structure is segmented into discrete flaps and web panels that can be independently formed and secured. This segmentation simplifies the manufacturing process by allowing each component to be formed through standard folding operations while still achieving firm retention through the modular assembly.
Solution Approach 2:
The hinge lines are designed to self-align and self-secure the flaps into position during the formation process. The structure utilizes its own geometric configuration to ensure proper assembly without requiring complex external tools or multi-step manufacturing procedures.
Data Source
AI summary
Aspects of the disclosure relate to a carton for packaging one or more articles, a blank for forming the carton and a method of packaging articles. The carton (90) comprises a plurality of primary panels (12, 14, 16, 18, 20) for forming a tubular structure and an end closure structure for at least partially closing an end of the tubular structure. The primary panels (12, 14, 16, 18, 20) include a top panel (16). The end closure structure comprises a top end closure flap (28A/28C) having a handle opening, a first side end closure flap (24A), and a web panel (26A) coupling the top end closure flap (28A/28C) with the first side end closure flap (24A). The web panel 26A is hingedly connected to the top end closure flap (28A/28C) as well as to the first side end closure flap (24A). The top end closure flap (28A/28C) is connected to the top panel (16) by at least one corner panel (40A, 40B, 40C).