Connected Blanks for Article Carrier with Frangible Connections
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Solution Overview
Problem
Existing carton packaging solutions require significant material and often result in wastage, lack strength for holding large weights, and do not securely retain articles during transport.
Innovation Solution
A set of connected blanks with frangible connections and hinged panels that can form multiple article carriers without the need for cutting tools, allowing for secure retention and easy assembly around articles, with engaging tabs and side panels that automatically break when folded to form distinct carriers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional carton packaging is used, then articles can be contained, but significant material wastage occurs and material usage is high
Solution Approach 1:
The blank is divided into multiple panels (engaging panel, side panels, end panels) connected by creases, allowing each panel to be folded into position to form a three-dimensional carrier structure. This segmentation enables the same material to be reused efficiently across multiple packaging units without requiring additional material for assembly components.
Solution Approach 2:
Multiple functional elements are merged into a single integrated blank structure. The engaging panel, side panels, and end panels are combined in one piece with pre-defined creases and aperture openings, eliminating the need for separate components, fasteners, or additional material layers that would increase overall material consumption.
2Strength
If traditional carton structures are used, then articles can be contained, but insufficient strength is provided for holding large weights
Solution Approach 1:
The blank is pre-formed with creases and aperture openings positioned to receive articles before final assembly. The engaging panel is pre-configured with aperture openings that guide article placement, and side panels are pre-angled to fold into protective positions, creating a strength-optimized structure without requiring additional material reinforcement.
Solution Approach 2:
The three-dimensional folded structure creates curved surfaces and angled panels that distribute mechanical loads more effectively than flat structures. The folded side panels and end panels form a box-like geometry with optimized stress distribution, enhancing weight-bearing capacity while maintaining material efficiency.
3Reliability
If traditional article retention methods are used, then articles can be contained, but articles are not securely retained during transport
Solution Approach 1:
The carrier structure automatically engages and secures articles through its inherent geometric design. The aperture openings in the engaging panel and the folded side panels create a self-contained cavity that naturally holds articles in place during transport, eliminating the need for additional fasteners, straps, or complex retention mechanisms.
Solution Approach 2:
The side panels and end panels are folded inward to create a nested, cavity-like structure that cradles the article. This nested configuration provides secure retention through the three-dimensional enclosure formed by the folded panels, ensuring articles remain stable during handling and transport without additional retention components.
4Manufacturing precision
If cutting tools are used to form carriers, then precise shapes can be achieved, but additional tooling requirements increase complexity
Solution Approach 1:
The crease lines and aperture openings are formed through scoring or punching operations that create permanent folds and openings in the blank material. This mechanical formation process replaces the need for complex cutting tools or multi-step forming processes, achieving precise carrier shapes through simple, repeatable operations that can be performed with basic packaging equipment.
Data Source
AI summary
Aspects of the disclosure relate to a top engaging article carrier (90) for packaging one or more articles blanks (10A, 10B, 10C, 10D) for forming the carrier (90) and a method of forming the carrier (90). An aspect provides a plurality of connected blanks (1), comprising two or more blanks (10A, 10B, 10C, 10D) each for forming an article carrier (90). Each blank (10A, 10B, 10C, 10D) comprises an engaging panel (12) having at least one article-receiving device (RT1) and a pair of side or shoulder panels (20, 22) hingedly connected to opposing sides of the engaging panel (12). A first side panel (20) of a first one of the two or more blanks (10A, 10B, 10C, 10D) is frangibly connected to an adjacently disposed side panel (22) of a second one of the two or more blanks (10A, 10B, 10C, 10D) by one or more frangible connections (N). The frangible connections (N) are broken automatically in response to application of the plurality of connected blanks (1) to a group of articles (B).