Corrugated Cardboard Blank With Corner Compression Members

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Solution Overview

Problem

Existing corrugated cardboard production lines face challenges in adapting to diverse requirements due to the need for producing boxes with varying formats and customization, leading to increased burden and inefficiency.

Innovation Solution

A blank design for corrugated cardboard boxes featuring a chassis with specific crease lines and integrated compression members, allowing for flexible production of different box types by optimizing material distribution and reducing weight where necessary.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional corrugated cardboard blanks are used to produce boxes with varying formats and customization, then diverse box requirements can be met, but the burden on production lines increases significantly

Engineering Contradiction:

Improveability to produce different box formatsVSAvoidburden on production lines

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies a universal blank design with standardized crease lines and compression member positions that can produce multiple box formats. The chassis has four first parallel crease lines and two intersecting crease lines that define panels and flaps, allowing the same blank structure to be adapted for different box sizes and configurations by adjusting only the compression members, not the entire production line

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The blank is segmented into distinct functional zones: a chassis with standardized crease lines defining panels and flaps, and separate compression members that can be independently positioned. This segmentation allows the production line to maintain a standardized chassis production process while only varying the compression members to meet different box format requirements

Inventive Principle:

Principle #1Segmentation

2Weight of moving object

If fiber content is reduced to decrease box weight, then material usage and weight are reduced, but box strength may be compromised

Engineering Contradiction:

Improvebox weightVSAvoidbox strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent applies local quality by concentrating fiber material specifically in the compression members at corner positions where strength is most needed for load-bearing and stacking. The rest of the chassis uses reduced fiber content, achieving weight reduction while maintaining overall box strength through strategic material placement in high-stress areas

Inventive Principle:

Principle #3Local quality

3Strength

If compression members are added to reinforce box corners, then box strength is improved, but material usage and complexity increase

Engineering Contradiction:

Improvecorner strengthVSAvoidfiber content

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The reinforcement function is segmented from the main chassis structure and implemented as separate, standardized compression members. These modular components are positioned at corner locations and can be produced independently, allowing strength enhancement without requiring increased fiber content throughout the entire blank, thus adding minimal material while maximizing structural reinforcement

Inventive Principle:

Principle #1Segmentation

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

Enables production of boxes with reduced fiber content and weight while maintaining strength, adapting to diverse requirements with minimal material adjustments, achieving up to 29% less fiber usage compared to conventional methods.

Implementation Method 1

two compression members of corrugated cardboard glued to an internal face of the chassis in correspondence of areas at least bordering on both sides at least a part of a respective length of the second crease line

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS12420978B2Blank and box obtainable therefrom

Publication Date: 2025.09.23 DS SMITH PLC

AI summary

A blank is provided which has a chassis of corrugated cardboard where a series of a quadrangular closure flap, a quadrangular cover panel, a first quadrangular lateral panel, a quadrangular bottom panel and a second quadrangular lateral panel are individuated by crease lines. Each panel is provided with left and right quadrangular flaps, respectively. The blank has four compression members of corrugated cardboard glued to an internal face of the chassis in correspondence of areas bordering the first and second quadrangular panels and the respective left and right quadrangular flaps. A box obtainable from the blank by folding is also provided.