Carton Handle Stress-Relieving Score Pattern
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Solution Overview
Problem
Existing beverage carton designs face challenges in maintaining structural integrity and cost-effectiveness, particularly when using thinner paperboard materials, as they often suffer from tearing and buckling issues due to inadequate stress distribution around the carrying handle.
Innovation Solution
The design incorporates a carton blank with stress-relieving score lines positioned relative to the carrying handle to distribute lifting stresses, ensuring the carton's structural integrity is maintained without compromising its strength, even when made from thinner paperboard, and includes reinforcing panels to enhance the carton's stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thicker, denser paperboard stock is used to maintain carton strength, then the structural integrity and tear resistance of the carton is improved, but the manufacturing cost increases
Solution Approach 1:
The patent applies local quality by creating a handle reinforcement structure with varying paperboard thickness. The handle area uses thicker paperboard (e.g., 0.060 inches) specifically where stress concentration occurs, while other areas of the carton use thinner, more economical paperboard (e.g., 0.047 inches). This localized thickening provides the necessary strength at the handle without increasing the cost of the entire carton.
Solution Approach 2:
The patent employs composite materials by combining multiple layers of paperboard with different thicknesses and potentially different material properties. The handle reinforcement structure consists of a base layer and an additional reinforcement layer, creating a composite structure that optimizes both strength and cost efficiency.
2Ease of manufacture
If thinner, less expensive paperboard is used to reduce manufacturing cost, then the manufacturing cost decreases, but the carton becomes prone to tearing and buckling under lifting loads
Solution Approach 1:
The patent applies local quality by creating a handle reinforcement structure with varying paperboard thickness. The handle area uses thicker paperboard (e.g., 0.060 inches) specifically where stress concentration occurs, while other areas of the carton use thinner, more economical paperboard (e.g., 0.047 inches). This localized thickening provides the necessary strength at the handle without increasing the cost of the entire carton.
Solution Approach 2:
The patent applies preliminary action by pre-reinforcing the handle area during the carton manufacturing process. The handle reinforcement structure is built into the carton blank before the carton is put into service, ensuring that the strengthened handle area is ready to withstand lifting loads from the outset.
3Strength
If stress-relieving lines are introduced to distribute lifting forces, then the structural integrity of the carton is improved, but the complexity of the carton design and manufacturing process increases
Solution Approach 1:
The patent applies segmentation by dividing the handle area into multiple sections with score lines. These score lines create controlled separation planes that allow the handle structure to flex and distribute stresses more effectively, preventing catastrophic failure while maintaining overall structural integrity.
Solution Approach 2:
The patent applies preliminary action by pre-reinforcing the handle area during the carton manufacturing process. The handle reinforcement structure is built into the carton blank before the carton is put into service, ensuring that the strengthened handle area is ready to withstand lifting loads from the outset.
4Device complexity
If conventional handle designs are used without additional reinforcement, then the manufacturing process remains simple, but the handle area is prone to tearing and failure under load
Solution Approach 1:
The patent applies local quality by creating a handle reinforcement structure with varying paperboard thickness. The handle area uses thicker paperboard (e.g., 0.060 inches) specifically where stress concentration occurs, while other areas of the carton use thinner, more economical paperboard (e.g., 0.047 inches). This localized thickening provides the necessary strength at the handle without increasing the cost of the entire carton.
Solution Approach 2:
The patent applies preliminary action by pre-reinforcing the handle area during the carton manufacturing process. The handle reinforcement structure is built into the carton blank before the carton is put into service, ensuring that the strengthened handle area is ready to withstand lifting loads from the outset.
Data Source
AI summary
A carton blank is assembled into a carton for beverage containers, the blank having a number of panels including a top panel, a bottom panel and a pair of side panels each joined by a fold line to an adjacent one of the panels. A number of end flaps are each joined by an end flap fold line to one of the panels and the end flaps are adapted to be folded upon selected other end flaps to form composite end panels of the carton. A carrying handle is formed in a selected one of the panels and adapted to be grasped by a user to carry the erected carton filled with the beverage containers. A pattern of stress-relieving score lines are formed in the carton blank to produce a desired buckling of the carton when erected, filled and lifted to avoid tearing of the carton material.