Corrugated Paperboard Container Edge Sealing for Bulge Resistance
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Solution Overview
Problem
Bulk material containers face issues with bulge resistance during stacking and infiltration of particulates due to the expansion of leaf products, which can lead to safety hazards and product loss, and existing corrugated paperboard containers have open edges that allow dust and debris to enter.
Innovation Solution
A reinforced bulk materials container design featuring corrugated paperboard blanks with flute members sandwiched between liner sheets, scored to form foldable panels with tabs that overlay and attach to the edges of flaps, sealing the channels and preventing particulate infiltration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If corrugated paperboard blanks with open edges are used, then manufacturing simplicity is maintained, but particulate infiltration into channels occurs
Solution Approach 1:
The patent applies this principle by using liner sheets that extend beyond the flute members to form flaps, creating a flexible sealing barrier that closes the open corrugated channels while maintaining the corrugated structure's integrity and manufacturability
Solution Approach 2:
The patent extends the liner sheets from the two-dimensional corrugated plane into the third dimension by forming flaps that extend beyond the flute members, creating a three-dimensional seal that blocks particulate infiltration while maintaining structural simplicity
2Productivity
If leaf products are compressed and stored in container, then storage efficiency is improved, but container walls experience forcing pressure causing bulge
Solution Approach 1:
The patent uses composite corrugated paperboard construction with multiple layers including flute members sandwiched between liner sheets, creating a composite structure that resists bulging from internal pressure while maintaining storage efficiency
Solution Approach 2:
The patent utilizes the natural curvature and arching of the corrugated flute structure, which provides inherent strength and bulge resistance through its curved geometry that distributes internal pressure more effectively
3Reliability
If top flaps are used to close container, then sealing function is provided, but flaps buckle or bulge under expanding leaf product pressure
Solution Approach 1:
The patent uses flexible liner sheet flaps that can accommodate the expanding leaf products while maintaining the seal, allowing the flaps to flex without buckling or breaking
Solution Approach 2:
The patent modifies the physical parameters of the flaps by extending the liner sheets beyond the flute members and attaching them to create a more robust flap structure that resists buckling under pressure while maintaining sealing functionality
Data Source
AI summary
A bulk materials container having a first wall-forming blank of corrugated paperboard sheets made of at least a flute member and a liner sheet, and scored to provide a series of main panels foldably joined together at opposing edges with each main panel having opposing top and bottom flaps foldably joined to respective edge portions and laminated to a second wall-forming blank having at least a flute member attached to a liner sheet scored to provide a series of main panels each having opposing top and bottom flaps foldably joined to respective edge portions, and a liner sheet and one of the first or second blanks extending beyond a distal edge of the respective top and bottom flaps, and folded over the distal edge and attached adhesively to the opposing surface so that the open channels of the flutes at the distal edge are covered.