Corrugated Container Walls with Multi-Directional Fluting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional collapsible box-like containers made from corrugated board suffer from poor compression strength, exposed internal edges, and adhesive failures, leading to structural issues and an unfinished appearance.
Innovation Solution
The container design incorporates a combination of horizontal and vertical corrugated board layers in its side and end walls, with a folding mechanism that creates a multi-layered structure for enhanced compression strength and smooth interior surfaces, and strategically placed glue points to prevent adhesive failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If horizontal fluting is used in corrugated board walls, then the container is easier to manufacture and collapse, but compression strength deteriorates
Solution Approach 1:
The patent transitions from single-direction (horizontal) fluting to multi-directional fluting by adding vertical fluting in overlapping layers. This dimensional change in fluting orientation allows the wall to maintain collapseability while gaining compression strength through the vertical dimension.
Solution Approach 2:
The patent creates a composite wall structure by combining horizontal fluting and vertical fluting in overlapping layers. This composite approach integrates the benefits of both fluting directions, achieving both collapseability and compression strength that neither single fluting direction could provide alone.
2Adaptability or versatility
If corner panels are folded inward to create knock-down feature, then the container becomes collapsible, but exposed edges are created causing snagging hazards
Solution Approach 1:
The patent extracts the problematic exposed edges by folding additional panels over the corner panels. These covering panels are specifically designed to conceal the sharp edges created by the knock-down folding, removing the hazard while preserving the collapsible feature.
Solution Approach 2:
The patent implements a nested structure where additional panels are folded over and contain the corner panels within them. This nested arrangement allows the corner panels to provide knock-down functionality while being enclosed by the outer panels that hide the exposed edges.
3Ease of manufacture
If single layer corrugated board is used, then manufacturing is simpler and cost is lower, but compression strength is insufficient
Solution Approach 1:
The patent segments the wall structure into multiple overlapping layers instead of using a single thick layer. Each layer maintains simple corrugated board construction, but the segmented multi-layer arrangement collectively provides the required compression strength while keeping individual manufacturing steps simple.
4Quantity of substance
If adhesive is applied at minimal points to reduce cost, then manufacturing cost is lower, but adhesive failure occurs under compression
Solution Approach 1:
The patent designs the panel geometry and overlap configuration in advance to create natural mechanical interlocking and compression distribution. This preliminary structural design ensures that adhesive bonds are distributed across optimized contact areas, preventing failure under compression without requiring excessive adhesive quantity.
Data Source
AI summary
The present invention is directed to a container having increased compression strength. Embodiments of the container comprise a pair of opposing side walls, each of which may include at least one layer of corrugated board having horizontal fluting and at least one layer of corrugated board having vertical fluting. Embodiments of the container also comprise a pair of opposing end walls, each of which may include at least one layer of corrugated board having horizontal fluting and at least one layer of corrugated board having vertical fluting. Embodiments of the container may be prepared from a single blank of corrugated board and may have a bottom surface that is integral with each of the side walls and each of the end walls so as to be considered leak proof. Embodiments of the container may also be configured to be collapsible to a substantially flat arrangement.