Corrugated Box With Open-Work Flaps For Access And Strength
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Solution Overview
Problem
Existing packaging solutions for pallets lack accessibility and structural integrity, requiring side tearing for access and being unsuitable for heavy or multi-level products due to lack of solidity.
Innovation Solution
A corrugated cardboard box design with a U-shaped front and rear wall, a tray base with flaps, and partially pre-cut portions or gluing points allowing manual separation of the lid from the tray, enabling easy access from both sides and top, and using different grades of cardboard for walls and base to enhance stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If walls are made solid and strong, then structural integrity is improved, but accessibility to products is worsened
Solution Approach 1:
The box is divided into two main parts: a solid lid for structural strength and a separate tray base for product storage. The lid can be completely removed from the tray by manual separation at the pre-cut portions, allowing full access to products while maintaining the integrity of the lid structure when closed.
Solution Approach 2:
The lid is extracted as a separate removable component from the tray base. This allows the lid to provide structural protection when needed, while the tray remains accessible for product storage and retrieval. The lid can be completely taken out by pulling at the pre-cut separation zones.
2Ease of operation
If open-work trays are used for accessibility, then product access is improved, but solidity and load-bearing capacity are worsened
Solution Approach 1:
The packaging is segmented into a strong lid structure and a separate tray base. The lid bears the compression loads when stacked, while the tray provides open-work accessibility for product placement and retrieval. This separation allows each component to be optimized for its specific function without compromise.
Solution Approach 2:
The solution moves the strength requirement from the tray base to the lid in the vertical dimension. The lid, being the upper component, is designed to withstand compression loads during stacking, while the tray base focuses on providing horizontal accessibility for products.
3Stability of the object's composition
If lid is permanently attached to tray, then structural stability is improved, but display-pack functionality and adaptability are worsened
Solution Approach 1:
The connection between lid and tray is made dynamic rather than static. The pre-cut portions enable the lid to be easily separated from the tray by manual force, transforming the structure from a fixed assembly to a separable one. This allows the packaging to adapt between closed-box mode (stable) and open-tray mode (versatile for display).
Solution Approach 2:
The lid and tray are pre-assembled with partial attachment through pre-cut portions during manufacturing, providing structural stability for transportation. However, the pre-cut portions are designed to allow easy separation later, enabling display-pack functionality at the point of use without requiring complex disassembly tools or processes.
4Ease of manufacture
If single-grade cardboard is used, then manufacturing simplicity is improved, but optimization of structural efficiency is worsened
Solution Approach 1:
Different grades of cardboard are assigned to different components based on their specific functional requirements. The lid uses higher-grade cardboard to withstand compression loads during stacking and transportation, while the tray base uses lower-grade cardboard sufficient for holding products and providing accessibility. This local differentiation optimizes structural efficiency without unnecessarily complicating manufacturing.
Data Source
AI summary
The invention concerns a generally parallelepiped corrugated box for packaging and transporting objects, the box comprising a lid formed by a lateral can-band carton including a front wall, a rear wall, and side walls and a top, and a tray forming a base including a central panel comprising four main sides each respectively provided with a first flap. The front and rear flaps are U-shaped and define each with the top a central recess enabling an object in the box to be gripped manually by a user from the side and/or from above. One or several partly precut portions and/or one or several bonding points enable the walls of the lid to be detached from the first flaps of the tray by manual separation resulting from a force applied perpendicularly to the walls.