Connected-Blank Carton Carriers for Cylindrical Article Retention
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Solution Overview
Problem
Existing cartons are inefficient in material usage, structural strength, and secure retention of cylindrical articles, particularly sleek or slim designs, while requiring complex assembly processes.
Innovation Solution
A set of connected blanks forming a top-engaging carrier with specific aperture distances and corner radii optimized for cylindrical articles, featuring stress-relieving cutlines in tabs to enhance structural integrity and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If cartons are formed from as little material as possible to reduce cost and waste, then material efficiency is improved, but structural strength and robustness deteriorate
Solution Approach 1:
The blank is divided into multiple connected units arranged in a matrix pattern, where each unit can be independently formed into a carrier. This segmentation allows for optimized material distribution - each carrier unit uses minimal material for its function while the connected matrix structure provides overall structural strength and stability during assembly and use.
Solution Approach 2:
Different regions of the blank have different structural characteristics optimized for their specific functions. The aperture regions are designed with specific dimensions and spacing to accommodate cylindrical articles, while the connecting regions between units are designed to provide structural support. The corner radius specifications ensure local structural integrity at critical stress points.
2Reliability
If complex assembly processes are used to ensure secure retention of articles, then retention reliability is improved, but ease of manufacture deteriorates
Solution Approach 1:
The blanks are pre-configured with apertures, tabs, and connecting features in specific geometric relationships during manufacturing. When assembled, the matrix arrangement of connected blanks automatically positions all retention features correctly, eliminating the need for complex alignment procedures or multi-step assembly operations.
Solution Approach 2:
Multiple carrier units are connected into a single integrated matrix structure, combining the retention functions of individual carriers while sharing common structural elements. This merging reduces the total number of separate assembly operations needed and simplifies the overall manufacturing process while maintaining secure retention through the interconnected design.
3Productivity
If aperture distances are reduced to accommodate more articles, then productivity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The matrix arrangement of connected blanks creates a regular, symmetric pattern where all apertures are equidistant from their neighbors in a consistent geometric progression. This equipotential design allows for standardized aperture positioning that can be achieved through simple repetitive manufacturing processes, reducing precision requirements compared to irregular arrangements.
Solution Approach 2:
The patent specifies particular relationships between aperture distances (D1, D2, D3) and corner radii (Rb) that optimize the balance between article density and manufacturability. By establishing these parameter relationships, the design enables higher productivity through closer aperture spacing while maintaining manufacturing feasibility through standardized dimensional relationships.
Data Source
AI summary
Aspects of the disclosure relate to a carrier for packaging one or more articles. The carrier is formed from a set of connected blanks each of which form a top engaging carrier, wherein the blanks are detachably connected together in a matrix fashion wherein each blank has a plurality of top-receiving apertures wherein a first distance (D1) between the respective centres of two adjacent ones of the apertures of a first blank is less than a second distance (D2) between the centre of a corner aperture of the first blank and the centre of the adjacent corner aperture of a second blank and wherein the first distance (D1) is less than a third distance (D3) between the centre of the corner aperture of the first blank and the centre of the adjacent corner aperture of a third blank.