Carton With Distinct Side Wall Edge Spacing For Structural Integrity
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Solution Overview
Problem
Existing carton designs for packaging multiple articles are inefficient in terms of material usage and structural strength, particularly in forming collapsible and automatically erectable gable top styles that minimize waste and maximize weight-bearing capacity.
Innovation Solution
A carton design featuring a plurality of walls with distinct edge distances and center fold lines for upper and lower end straps, allowing for collapsibility and automatic erection from a flat sleeve form, with hinged connections and securing panels to maintain structural integrity and facilitate easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the carton is designed to be collapsible for automatic erection, then material efficiency and ease of storage are improved, but structural strength and stability during transport are worsened
Solution Approach 1:
The carton is divided into multiple panels (front panel, back panel, side panels, end panels) connected by fold lines. This segmentation allows the structure to collapse into a compact form while maintaining structural integrity when erected, as each panel can be independently positioned to bear load.
Solution Approach 2:
The carton employs dynamic fold lines that allow transition between collapsed and erected states. The fold lines are designed to maintain structural strength in the erected state while enabling easy collapse for storage and transport, resolving the contradiction between strength and collapsibility.
2Strength
If the carton walls are made stronger to hold large weights, then load-bearing capacity is improved, but material usage increases and collapsibility is worsened
Solution Approach 1:
The carton features varying wall thicknesses and panel configurations at different locations. End panels and critical load-bearing areas have enhanced structure, while other areas use minimal material, optimizing strength where needed without increasing overall material usage.
Solution Approach 2:
By segmenting the carton into multiple panels with strategic fold lines, the structure achieves high load-bearing capacity through geometric configuration rather than material quantity. The segmented design allows weight distribution across multiple panels, reducing material requirements.
3Productivity
If the carton is designed as a multi-pack for shipping and distribution, then productivity and distribution efficiency are improved, but device complexity and manufacturing difficulty are worsened
Solution Approach 1:
The carton design serves multiple functions: it packages multiple articles, facilitates efficient shipping and distribution, and maintains structural integrity throughout the supply chain. The standardized panel and fold line configuration enables universal application across different product types while maintaining manufacturing simplicity.
4Strength
If the carton end panels are connected directly for structural stability, then strength is improved, but collapsibility and ease of assembly are worsened
Solution Approach 1:
The end panels are connected through dynamic fold lines rather than rigid direct connections. This allows the panels to be easily assembled and disassembled by folding while maintaining structural stability when in the erected state, as the fold lines provide flexible yet strong connections.
Data Source
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AI summary
A carton (90) for packaging one or more articles. The carton includes a plurality of walls which extend at least partially around an interior of the carton. The plurality of walls includes at least one of top (18) and bottom (12, 24) walls, a pair of opposed side walls (14, 16 and 20, 22) and a pair of opposed end walls (26a, 28a, 30a, 34a and 26b, 28b, 30b, 34b). Each of the side walls has opposed upper (17, 19) and lower edges (13, 23). The upper edges of the side walls are disposed at a first distance (dl) from each other. The lower edges of the side walls are disposed at a second distance (d2) from each other. The first distance is substantially different from the second distance. Each of the end walls includes an upper end strap (28b, 30b) and a lower end strap (26b, 34b).