Carton Stacking Support Structures for Flap Interference
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Solution Overview
Problem
Shipping containers made from paper, paperboard, and corrugated paperboard face issues when the depth exceeds the width, causing internal and external flaps to interfere, leading to potential weaknesses and material inefficiencies, especially in unit load building and handling.
Innovation Solution
A carton design featuring a blank with specific foldable panels and lines of weakness, allowing for the formation of a carton with vertically extending stacking support structures, which can be articulated to provide enhanced stacking strength without increasing material consumption, and includes features like L-shaped or triangular cross-sections and additional support panels for improved structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the depth of the shipping container is increased beyond its width, then the stacking strength is improved, but the internal and external flaps interfere with each other during machine erection
Solution Approach 1:
The patent removes material from the flaps in the form of slots to eliminate the interference between internal and external flaps during machine erection. This extraction of material allows the flaps to be properly positioned and secured without collision, resolving the manufacturing difficulty while preserving the deep container design for stacking strength.
Solution Approach 2:
The patent divides the flaps into multiple segments with intermediate sections between the internal and external flaps. These segmented structures include slots that allow proper positioning and securing of the flaps during machine erection, enabling the container to achieve both increased depth for stacking strength and proper flap assembly.
2Ease of manufacture
If material is removed from the flaps to prevent interference, then the machine erection is improved, but the structural strength and material efficiency are reduced
Solution Approach 1:
The patent segments the flaps into multiple sections with intermediate portions between the internal and external flaps. These intermediate sections are designed to be secured to the container body, distributing the structural load and maintaining strength despite the slots created for machine erection. The segmentation allows both manufacturing ease and structural integrity.
Solution Approach 2:
The patent incorporates slots and intermediate sections in the flap design before machine erection, allowing the flaps to be properly positioned and secured during the manufacturing process. This preliminary structuring ensures that the flaps can be erected without interference while maintaining adequate structural strength through the intermediate securing sections.
3Strength
If the container depth is increased, then the stacking support is improved, but the material consumption increases
Solution Approach 1:
The patent uses segmented flaps with intermediate sections that are secured to the container body, creating multiple support points that enhance stacking strength. This segmentation allows the container to achieve improved stacking support through structural design rather than simply increasing material quantity, thereby avoiding excessive material consumption.
Solution Approach 2:
The patent enhances stacking support by creating three-dimensional structural features through the segmented flap design and intermediate sections, rather than simply increasing the depth dimension. This dimensional approach to strengthening allows improved stacking support without linearly increasing material consumption.
Data Source
AI summary
Shipping containers having stacking support structures are provided. The shipping containers or cartons, are provided with three-panel inner support structures, in which the three panels form either triangular- (delta-) shaped cross-sections or L shaped cross-sections. In addition, the shipping containers or cartons, are provided with first outer support panels, and one or two second outer support panels. The shipping containers or cartons may be provided with no lid, one lid panel with closure panels for affixation to the end panels, or two lid panels, each with closure panels for affixation to the end panels.