Carton Handle With Hinged Gussets For Stress Distribution
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Solution Overview
Problem
Existing cartons with handles are inefficient in material usage, leading to potential tearing when carrying multiple articles, which increases production costs.
Innovation Solution
A carton design featuring a tubular structure with a handle that includes a main portion, gussets, and end portions hingedly connected to distribute stress, allowing the handle to fold around articles and reduce material usage while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a handle is added to the carton to enable carrying, then handling capability is improved, but material usage increases and tearing risk increases
Solution Approach 1:
The handle is merged with the carton structure by forming it from the same material using the same forming process. The handle integrates with the carton walls through hinged connections and fold lines, creating a unified structure that eliminates the need for separate handle components and reduces overall material usage.
Solution Approach 2:
The handle incorporates dynamic elements through hinged connections and fold lines that allow it to flex and adapt to the carton's structure. This dynamic design enables the handle to be formed from thinner material while maintaining strength, as it can accommodate stress through movement rather than rigid rigidity.
2Quantity of substance
If thinner material is used to reduce cost, then production cost decreases, but tearing risk increases when handle is engaged
Solution Approach 1:
The handle structure is segmented into multiple sections connected by hinged joints and fold lines. This segmentation allows stress to be distributed across multiple connection points rather than concentrated at a single location, enabling the use of thinner material while maintaining tearing resistance through distributed load bearing.
Solution Approach 2:
The handle design creates a composite structure where the same material serves multiple functions - both the carton walls and the handle are formed from the same material, but the handle's geometric configuration creates reinforced stress distribution patterns that enhance local strength without requiring additional material.
3Strength
If the handle is designed to fold around articles, then stress distribution is improved, but structural complexity increases
Solution Approach 1:
The handle uses dynamic fold lines and hinged connections that allow it to naturally conform to the carton's geometry and the articles within. This dynamic folding mechanism simplifies the overall structure by eliminating the need for complex rigid frameworks, achieving stress distribution through geometric configuration rather than structural complexity.
Data Source
AI summary
A carton includes a handle (160) for carrying the carton. The handle includes a handle flap (162a) with a main portion (174a), first (178a) and second (180a) gussets, and an end portion (176a). The main portion is hingedly connected to the first gusset along a first fold line (182a), the first gusset is hingedly connected to the second gusset along a second fold line (184a), and the second gusset is hingedly connected to the first end portion along a third fold line (120).


