Carton Packaging Blank With Integrated Wedging Part
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Solution Overview
Problem
Existing cardboard packaging solutions for groups of cartons fail to maintain the spacing and wedging of cartons in place without shape change, collapse, or failure, especially at high speeds and in complex production processes.
Innovation Solution
A flat cardboard blank design with a continuous spacing/wedging part formed by a longitudinally median transverse portion of the base panel and sections of the connecting panels, using irreversible-pivot double hinges and curved edge cutout lines to create stopping edges that stabilize the cartons without requiring additional stress on the wedging sub-parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spacing/wedging part is designed to be expanded in volume relative to the receiving part to wedge cartons, then the cartons can be spaced and wedged on their side walls, but the spacing/wedging part may change shape, collapse, or fail under stress
Solution Approach 1:
The spacing/wedging part is divided into multiple independent sub-parts (first spacing/wedging sub-part and second spacing/wedging sub-part), each capable of expanding and positioning independently. This segmentation prevents collapse by distributing mechanical stress across separate units rather than a single continuous structure
Solution Approach 2:
The spacing/wedging sub-parts are pre-configured with grooved pivoting lines that define hinge locations before assembly. This preliminary structuring ensures that when the blank is expanded in volume, the sub-parts automatically form stable triangular configurations with the base panel, preventing shape change during the wedging process
2Ease of manufacture
If grooved lines and cutout lines are used to create the spacing/wedging part from the base panel, then the cartons can be wedged on their side walls, but additional stress is required on the spacing/wedging sub-parts during assembly
Solution Approach 1:
The base panel is designed with strategically placed grooved lines that create built-in hinge locations before assembly. These pre-formed hinges cushion the stress during assembly by providing defined pivot points, eliminating the need for additional external stress on the spacing/wedging sub-parts during the wedging process
Solution Approach 2:
The grooved pivoting lines act as intermediary elements between the base panel and the spacing/wedging sub-parts. These grooved lines facilitate controlled rotation and positioning during assembly, mediating the stress transfer and reducing the force required to position the cartons correctly
3Stability of the object's composition
If the spacing/wedging part is designed to prevent carton movement and collision, then the cartons are stabilized in position, but the packaging process becomes more complex
Solution Approach 1:
The spacing/wedging function is merged directly into the base panel structure through integrated grooved lines and cutout patterns. This combination eliminates the need for separate spacing mechanisms or additional assembly steps, achieving carton stabilization without increasing packaging process complexity
Solution Approach 2:
The spacing/wedging sub-parts are designed to self-position and self-stabilize cartons through their geometric configuration and hinge mechanisms. The structure automatically wedges cartons in the correct position without requiring external adjustment or complex packaging processes, as the design itself provides the stabilizing action
Data Source
AI summary
A blank includes: two top panels, two side panels, two connecting panels, a base panel, a connecting element for the closing on itself of the blank that is expanded in volume; a receiving part, extending over a part of the base panel, for receiving wedging cartons by their bottom walls, and if necessary extending over the connecting panels; and a spacing/wedging part, coming from the base panel with cutout lines. The continuous spacing/wedging part is formed by a longitudinally median transverse portion of the base panel and a longitudinally median transverse portion, in two sections, of the two connecting panels, one section per connecting panel. The spacing/wedging part is limited in the transverse direction by two continuous and curved edge cutout lines of the spacing/wedging part, advancing overall in the longitudinal direction, whose segments form stopping edges.