Carton with Top and Bottom Hinge Panels for Retail Display
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Solution Overview
Problem
Existing carton designs fail to efficiently utilize space for retail products and do not provide a secure method to display and store multiple articles, especially when space behind retail signs needs to be accessed.
Innovation Solution
A carton design featuring a box structure with specific panel configurations and slots for tabs, allowing it to be assembled into a recessed form that can be attached to a flip sign, securing articles both when the sign is in place and when it is rotated for access to the rear storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If articles are stored behind a flip sign for retail display, then product accessibility is improved, but the space utilization and security of stored articles deteriorate
Solution Approach 1:
The carton is nested within the recess formed by the flip sign structure, with the carton's outer surface engaging the front surface of the flip sign. This nesting arrangement allows the carton to be securely stored behind the flip sign while maintaining accessibility when the sign is rotated, resolving the contradiction between security and ease of operation.
Solution Approach 2:
The flip sign is designed to be rotatable between a first position (blocking access) and a second position (allowing access). This dynamic movement enables the system to transition between secure storage and easy accessibility, resolving the contradiction by making the security state changeable based on operational needs.
2Volume of moving object
If a recess is formed between panels to store articles, then space utilization is improved, but the structural complexity and manufacturing difficulty increase
Solution Approach 1:
The carton is divided into multiple panels (front, back, top, bottom, and side panels) that can be separately formed and then assembled. This segmentation allows each panel to be manufactured independently using standard forming processes, reducing overall manufacturing complexity while creating the three-dimensional recess structure for efficient space utilization.
Solution Approach 2:
Multiple panels are merged together through joining operations to form the complete carton structure with integrated recesses. By combining simpler panel elements into a unified structure, the design achieves complex storage functionality without requiring each component to be individually complex, thus improving space utilization while managing manufacturing complexity.
3Reliability
If panels are connected with tabs and slots for secure assembly, then the reliability of assembly is improved, but the manufacturing precision requirements increase
Solution Approach 1:
Tabs and slots are positioned at specific locations on the panels rather than requiring uniform precision across entire surfaces. By concentrating precision requirements only at the localized tab-and-slot interfaces, the overall manufacturing precision requirement is reduced while maintaining high assembly reliability at critical connection points.
Solution Approach 2:
The tab-and-slot mechanism is designed to self-align during assembly, where the geometric shapes of the tabs and slots guide proper positioning without requiring external alignment tools or highly precise pre-positioning. This self-aligning feature reduces manufacturing precision requirements while ensuring reliable assembly.
Data Source
AI summary
The method includes first folding a top panel and a top hinge panel about a back panel and adhesively connecting the top hinge panel the back panel to form a first hinge, second folding a bottom panel and a bottom hinge panel about the back panel and adhesively connecting the bottom hinge panel to the back panel to form a second hinge, the first hinge and the second hinge being on first opposing edges of the back panel, and third folding a first side panel and a second side panel about the back panel to form a first wall and a second wall of a carton, the first wall and the second wall being on second opposing edges of the back panel.