Corrugated Tray With Integral Support Tabs For Blister Pack Stability
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Solution Overview
Problem
Conventional shipping and display trays require additional parts or excess material to maintain blister packs in an upright position during display, increasing complexity and cost.
Innovation Solution
An integrated tray made from corrugated paperboard with foldable design elements, including a tubular open-ended structure, apertures for article support, and removable dividers for stability and compression, allowing for modular assembly and ergonomic handling without glue, staples, or tape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If separate inserts or specially constructed folded walls are added to hold blister packs upright, then the stability of articles in upright position is improved, but the device complexity and material usage increase
Solution Approach 1:
The support structures are merged with the tray itself by forming integral support tabs and recesses as part of the single paperboard blank. The side walls include recesses that receive support tabs from adjacent trays, creating unified support functionality without separate inserts or additional parts.
Solution Approach 2:
The side walls serve multiple functions: they provide structural containment for the blister packs, include recesses for receiving support tabs, and form part of the stacking interface with adjacent trays. This multi-functionality eliminates the need for dedicated support structures.
2Stability of the object's composition
If additional parts such as inserts are used to support blister packs, then the stability of articles is improved, but the ease of manufacture deteriorates due to increased assembly steps
Solution Approach 1:
All support functionality is combined into the single paperboard blank from which the tray is formed. The support tabs and recesses are integral features of the blank itself, eliminating the need for separate inserts and simplifying manufacturing to a single forming operation.
Solution Approach 2:
The blank is segmented into functional zones including side walls with recesses and support tabs, allowing the single piece to perform multiple functions. The segmentation is achieved through die-cut patterns rather than separate components, maintaining ease of manufacture.
3Stability of the object's composition
If more material is used to form support structures, then the stability of articles is improved, but the loss of substance increases
Solution Approach 1:
The support structures are merged with the tray walls themselves rather than being separate additions. The recesses and tabs utilize the existing material of the side walls, providing support functionality without requiring additional paperboard beyond what is needed for the basic tray structure.
Data Source
AI summary
The present invention is to an integrated tray for holding and retaining a plurality of articles contained therein. The integrated tray comprises a tubular open-ended tray having a floor panel and an article support panel that is foldably joined to the floor panel in a spaced apart relationship. The article support panel includes a plurality of apertures formed therein to securely retain the plurality of articles therein. A girder is foldably joined to the floor panel and extending upwardly therefrom and is engaged with the article support panel to form the tubular open-ended tray. At least one divider is configured to be removably attached to the tubular open-ended tray. The at least one divider has at least one web panel extending transversely across the tray and at least one flange panel extending longitudinally of the tray.