Corrugated Container Reinforcement Panel Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing bulk material containers face issues with manufacturing efficiency, top-load compressive strength, and contamination due to adhesive waste and expansion of contents, leading to potential buckling and stacking instability.
Innovation Solution
The container design incorporates reinforcement panel assemblies with U-shaped channels and stiffeners between corrugated paperboard blanks to enhance structural integrity and prevent bulging, using adhesive attachment of support members to secure the panels and improve stacking stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If elongated corrugated blanks are used to form four wall panels, then the container can be assembled, but the blanks become heavy and awkward to handle and position
Solution Approach 1:
The exterior blank is divided into four separate panels that are attached to the interior blank sequentially rather than using one long 180-inch blank. This segmentation makes each panel lighter and easier to handle, position, and attach during assembly while still forming the complete container structure.
2Reliability
If adhesive is used to secure rigid members to the blank, then the members are secured, but overglue extends outwardly causing waste and contamination
Solution Approach 1:
The harmful overglue is extracted or removed from the edges of the blank before the blank is folded. This prevents the adhesive from extending outwardly and contaminating the interior surface that faces the bulk materials, while still maintaining secure attachment of the rigid members to the blank.
3Productivity
If the container is designed for stacking, then storage efficiency is improved, but the containers need sufficient top load compressive strength to prevent collapse
Solution Approach 1:
The container uses a composite structure combining the interior corrugated blank, exterior corrugated blank, and reinforcement panel assemblies with wooden members to achieve sufficient top load compressive strength for stacking, while maintaining the productivity benefits of stackable design.
4Reliability
If straps are used to resist expansion of contents, then the closure flaps are held closed, but the expansion presses against walls causing buckling or bulging
Solution Approach 1:
Reinforcement panel assemblies with wooden members are applied locally at specific positions on the container walls to provide additional structural support where needed. This prevents buckling and bulging of the walls and closure flaps caused by content expansion, while allowing the straps to effectively hold the flaps closed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides improved manufacturing efficiency, increased top-load compressive strength, and reduced contamination risks, ensuring safer and more reliable storage and transportation of bulk materials by preventing buckling and bulging.
Implementation Method 1
A pair of liner sheets are each folded to define a U-shaped channel having opposing interior surfaces. The opposing interior surfaces each attach to a respective one of the opposing planar sides of the reinforcement panel assembly
Implementation Method 2
The wall-forming blanks, being folded on the respective scores, forms the side walls of the bulk materials container and the respective closure flaps, being folded on the respective scores, close an end opening thereof
Data Source
AI summary
A first and second blank of corrugated paperboard scored to define wall panels that receive a reinforced wall panel assembly having a central pad with opposing vertical members and opposing horizontal members and a pair of U-shaped channels each attached in overlying relation with the pad, the vertical members and a respective horizontal member to secure the wall panel assembly together. A method of making a bulk materials container is disclosed.