Carton Panel Interlocking Device with Foldable Tabs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current packaging solutions for multi-packs face challenges in minimizing material usage while ensuring strength and stability for transporting large weights, particularly in forming secure connections between carton panels.
Innovation Solution
A locking mechanism comprising a female tab on one panel and a male tab on another, both foldably coupled along non-linear lines, with weakened lines facilitating folding into a braced position to secure the panels together, reducing material waste and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional locking mechanisms are used to secure panels, then the panels are held firmly together, but the material usage increases and structural complexity increases
Solution Approach 1:
The locking mechanism is divided into separate functional elements: a male tab with bracing flaps and a female tab with a recess. This segmentation allows each component to perform its specific function efficiently without requiring excessive material for the entire locking structure.
Solution Approach 2:
The male tab incorporates non-planar bracing flaps that extend in three dimensions, creating a braced position that provides structural strength without requiring additional material layers or complex assembly. The flaps fold out from the plane of the male tab to engage with the female tab recess.
2Strength
If traditional locking mechanisms are used to secure panels, then the panels are held firmly together, but the structural complexity increases
Solution Approach 1:
The locking mechanism uses foldable bracing flaps that transition from a flat state during assembly to a braced three-dimensional position during locking. This dynamic transformation allows the structure to gain strength only when needed, maintaining simplicity during manufacturing and assembly.
Solution Approach 2:
The male tab's bracing flaps automatically engage with the female tab's recess through folding action, creating self-bracing without requiring additional fasteners, adhesives, or complex alignment mechanisms. The structure serves its own locking function through the geometry and folding action of its components.
3Loss of substance
If minimal material is used for the locking mechanism, then material waste is reduced, but the resistance to disengagement decreases
Solution Approach 1:
The bracing flaps are designed with curved or angled geometries that fold into a braced position, creating interlocking surfaces that resist disengagement forces. The non-linear fold lines and angled configurations provide mechanical advantage and friction resistance without requiring excessive material.
Solution Approach 2:
The locking mechanism integrates multiple functional features into single composite components: the male tab combines the locking protrusion with integrated bracing flaps, while the female tab combines the recess with corresponding bracing surfaces. This composite design achieves high reliability with minimal material by eliminating separate components.
Data Source
AI summary
A locking device for a carton includes a first part (F) defined in a first panel (12) and a second part (M) defined in a second panel (14). The first part includes a female tab (22) struck from the first panel and foldably coupled thereto. The second part includes a male tab (20) struck from the second panel and foldably coupled thereto. The male tab is hinged to the second panel by a first non-linear fold line (24) and is receivable in an aperture created by folding the female tab out of the plane of the first panel so as to secure the first and second panels together. The male tab includes at least one weakened line (28) for facilitating folding of the male tab about the first non-linear fold line (24). An edge (30) of the female tab braces against the male tab so as to maintain the male tab in a folded or locked configuration.