Carton With Exterior Stacking Tabs And Smooth Interior

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Solution Overview

Problem

Existing carton designs for transporting and storing fresh produce suffer from irregular interior surfaces due to inwardly-folded stacking tabs and end flaps, which can damage contents, obscure branding, and increase the risk of 'finger poke' damage, while also being aesthetically unappealing and inefficient in presenting promotional content.

Innovation Solution

A carton design featuring a blank with a treated side for exterior surfaces and an untreated side for the interior, including smooth, uninterrupted surfaces for the side and end walls, and handle structures that do not extend completely through the end walls, allowing for secure stacking, ventilation, and presentation of branding without risking damage to contents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If inwardly-folded stacking tabs and inner end flaps are used to form carton structure, then stacking capability and structural integrity are improved, but interior surface smoothness and visual cleanliness deteriorate

Engineering Contradiction:

Improvestacking capabilityVSAvoidinterior surface smoothness

Core Design Contradiction:

Stability of the object's compositionVSShape

Solution Approach 1:

The harmful inwardly-folded stacking tabs and inner end flaps are extracted and removed from the carton interior. Instead, stacking tabs are positioned on the exterior of the carton, and end flaps are configured to close the ends without protruding into the interior space, thereby eliminating interior surface irregularities while preserving stacking functionality.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The stacking tabs are relocated from the interior dimension to the exterior dimension of the carton. This dimensional relocation allows the tabs to perform their stacking function externally without compromising the smoothness and visual quality of the interior surface.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If inwardly-folded structures are used for carton assembly, then structural integrity is improved, but risk of damage to contents deteriorates

Engineering Contradiction:

Improvestructural integrityVSAvoidrisk of damage to contents

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The potentially harmful inwardly-folded structures are extracted and removed from the carton interior. The design eliminates protruding elements that could puncture or damage contents, while maintaining structural integrity through alternative configurations of end flaps and stacking tabs positioned on the exterior or configured to close without intrusion.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If inwardly-folded stacking tabs and end flaps are used, then carton assembly is achieved, but visibility and clarity of printed content on interior walls deteriorates

Engineering Contradiction:

Improvecarton assemblyVSAvoidvisibility of printed content

Core Design Contradiction:

Ease of manufactureVSLoss of information

Solution Approach 1:

The obstructing inwardly-folded structures are extracted and removed from the interior surface. This clearance allows printed content on the interior side and end walls to be fully visible and clear to consumers, while the carton assembly functionality is maintained through alternative flap and tab configurations.

Inventive Principle:

Principle #2Taking out (Extraction)

4Ease of operation

If handles extending completely through end walls are used, then handling capability is improved, but risk of finger poke damage to contents deteriorates

Engineering Contradiction:

Improvehandling capabilityVSAvoidrisk of finger poke damage

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

Instead of handles extending completely through the end walls, the handles are configured to extend only partially through the wall thickness. This partial penetration provides sufficient gripping surface for handling while eliminating the through-opening that would allow fingers to poke through and damage contents.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS10421576B2Carton, blank, and method of folding

Publication Date: 2019.09.24 WESTROCK SHARED SERVICES LLC

AI summary

A carton defines a bottom wall, a first side wall coupled to the bottom wall, a second side wall disposed opposite the first side wall and coupled to the bottom wall, a first end wall coupled to both the bottom wall and first and second side walls, and a second end wall disposed opposite the first end wall and coupled to both the bottom wall and the first and second side walls. The carton is formed from a blank having a first side and a second side disposed opposite said first side. The first side defines the interior surface of the bottom wall and the interior and exterior surfaces of the first and second side walls and the first and second end walls.