Carton End Closure Structure With Hinged Web Panel
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Solution Overview
Problem
Existing cartons lack an efficient end closure structure that provides secure retention and handling of articles while minimizing material usage and ensuring strength for transporting large weights, with a focus on environmental sustainability.
Innovation Solution
A carton design featuring a tubular structure with a top end closure flap, side end closure flaps, and web panels hingedly connected along fold lines, where the web panels are separated by disconnection elements forming handle reinforcing portions, allowing for a carrying handle and secure closure, and optionally including display windows for article presentation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional end closure structures are used, then the carton can be assembled, but the structural integrity and handling strength are insufficient
Solution Approach 1:
The end closure structure is divided into multiple functional components: top end closure flaps for sealing, side end closure flaps for lateral support, and web panels for interconnection. Each segment performs a specific function, collectively providing enhanced structural integrity while maintaining manageable complexity through modular design.
Solution Approach 2:
The web panels are hingedly connected along fold lines that extend into the side end closure flaps, creating a three-dimensional reinforcement structure. This dimensional approach transforms flat panels into a volumetric closure system that provides superior strength without proportionally increasing material usage.
2Loss of substance
If material usage is minimized for environmental sustainability, then waste is reduced, but the strength for transporting large weights is compromised
Solution Approach 1:
The end closure structure utilizes thin web panels and flaps made from paperboard or similar flexible materials. These thin elements are strategically configured with hinged connections and fold lines to provide maximum strength-to-weight ratio, minimizing material usage while maintaining the capability to secure heavy article loads.
Solution Approach 2:
The hinged connections and fold lines enable the end closure structure to dynamically adapt to the articles being transported. The structure can flex and conform to different load configurations, providing optimal support with minimal material while maintaining strength for transporting large weights.
3Ease of manufacture
If the end closure structure is simplified, then manufacturing is easier, but the handling and retention of articles is less secure
Solution Approach 1:
The closure structure is segmented into top flaps, side flaps, and web panels that can be manufactured and assembled independently. This segmentation simplifies the manufacturing process while the interconnecting hinged joints ensure reliable article retention through coordinated movement and secure engagement of all components.
Solution Approach 2:
The web panels act as intermediary elements that connect the top end closure flaps to the side end closure flaps. These web panels provide both structural support for reliable article retention and a simplified assembly pathway, as they serve as the foundational framework to which other components are attached.
4Ease of operation
If handle reinforcement is added for better handling, then carrying capability is improved, but material usage increases
Solution Approach 1:
The side end closure flaps serve multiple functions: they provide lateral support for the carton structure, participate in the end closure sealing mechanism, and simultaneously form handle reinforcing portions. This multi-functionality improves handling ease without requiring additional dedicated handle materials, as the same structural elements perform multiple roles.
Solution Approach 2:
The handle reinforcing portions are merged with the side end closure flaps, combining the structural support function with the handle reinforcement function. This integration ensures that the materials used for side wall support also provide handling capability, eliminating the need for separate handle components and reducing overall material consumption.
Data Source
Figure 1
Figure 1A
Figure 2
AI summary
Aspects of the disclosure relate to a carton (90) for packaging one or more articles, a blank (10) for forming the carton and a method of packaging articles. The carton comprises a plurality of panels forming walls of a tubular structure including a top wall, a first side wall (14a), a base wall (12, 20), and a second side wall (18a). An end closure structure (24b, 26b, 28b, 30b, 30d, 32b, 34b, 36b, 38b, 40b, 42b, 44b, 50b) at least partially closes an end of the tubular structure. The end closure structure includes: a top end closure flap (30a,30b) having a handle opening forming (H1, H2) a carrying handle; a side end closure flap (24a, 36a) coupled to one of the first and second side walls; and a web panel (28a, 28b, 32a, 32b) interconnecting the top end closure flap (30a,30b) to the side end closure flap. The web panel is hingedly connected to the top end closure flap and is hingedly connected to the side end closure flap (24a, 36a, 24b, 36b) along a fold line (37).