Octagonal Container Substrate With Gapless Corner Flange Assembly
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Solution Overview
Problem
Existing container manufacturing processes are complex, require multiple tools, and often result in containers with poor aesthetics and durability due to gaps and edges at the corners.
Innovation Solution
A container substrate design with gapless corner flange sections, attachment flaps, and de-nesting features, allowing for easy assembly and separation, and optional adhesive or mechanical attachment methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional container manufacturing processes are used, then containers can be produced, but they have gaps and edges at corners resulting in poor aesthetics and durability
Solution Approach 1:
The container substrate is divided into distinct functional sections: corner flange sections with attachment flaps, longitudinal side surfaces, and transversal side surfaces. This segmentation allows each corner section to be independently formed with overlapping attachment flaps that eliminate gaps between corners and sides, while maintaining a manageable manufacturing process through standardized substrate cutting and folding operations.
Solution Approach 2:
The container substrate is pre-formed with integrated corner flange sections that include attachment flaps extending from the corner sides. These attachment flaps are preliminarily positioned to overlap with adjacent longitudinal and transversal side surfaces, ensuring gapless corners are achieved during assembly without requiring complex post-processing or multiple manufacturing steps.
2Productivity
If traditional container assembly methods are used, then containers can be assembled, but they require a large number of tools and multiple steps
Solution Approach 1:
Multiple container sections (corner flange sections, longitudinal side surfaces, transversal side surfaces) are merged into a single integrated substrate blank. The substrate includes pre-configured valley fold ruled lines and mountain fold ruled lines that guide assembly, allowing all sections to be joined in a streamlined process using fewer tools and steps compared to traditional multi-component assembly methods.
Solution Approach 2:
The container substrate is designed with self-aligning features including valley fold ruled lines and mountain fold ruled lines that automatically guide the folding and assembly process. The overlapping attachment flaps at corners self-position during assembly, reducing the need for complex tooling and multiple manual adjustment steps, thereby improving productivity with simpler equipment.
3Reliability
If traditional container designs are used, then containers can be manufactured, but flange sections may come apart at corners during handling
Solution Approach 1:
The corner flange sections are designed with nested overlapping attachment flaps where the corner attachment flap overlaps both the longitudinal side surface attachment flap and the transversal side surface attachment flap. This nested overlapping arrangement creates multiple layers of bonded material at each corner joint, significantly enhancing durability and preventing separation during handling compared to traditional single-layer joints.
Solution Approach 2:
The overlapping attachment flaps at corners create a composite structure where multiple substrate layers are bonded together through adhesive application on attachment flap surfaces. This composite construction at corner joints distributes mechanical stresses across multiple bonded interfaces, improving reliability and preventing flange separation during container handling and use.
Data Source
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AI summary
The invention relates to a container (16) assembled from a container substrate (1). The container (16) and container substrate (1) comprise an octagonal bottom surface plate (2), a pair of longitudinal side surface plates (3), a pair of transversal side surface plates (7) and four corner side surface plates (9). The corner side surface plates (9) comprise attachment flaps (11) connected via valley fold ruled lines on either side edge (9c), wherein the attachment flaps (11) are arranged to be attached to the respective longitudinal side surface plate (3) and transversal side surface plate (7) arranged on either side of the corner side surface plates (9) in an overlapping arrangement. Corner flange section (10) comprising corner flange sub sections (10c) extend transversely and longitudinally past a top edge (9b) of the respective corner side surface plate (9).