Cardboard Crate Corner Locking for Stackability
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Solution Overview
Problem
Existing cardboard crates face challenges in achieving high inherent stability and stackability, with previous solutions either compromising on strength or limiting directional stacking protection.
Innovation Solution
The design incorporates foldable bottom sections with snap-in tabs, inwardly folded edge flaps forming reinforced longitudinal edge sections with upward corner projections that engage in recessed base sections, ensuring form-fitting locking and load distribution across parallel bearing surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If upwardly protruding wall attachments are provided for stacking crates, then stackability is achieved, but the inherent strength is low and damage to attachments is expected
Solution Approach 1:
The crate structure is segmented into distinct functional zones: corner sections with upwardly protruding locking projections for stacking, and longitudinal edge sections with inwardly folded edge flaps for load bearing. This segmentation allows each part to specialize in its function, with corner sections providing stacking capability and edge flaps providing strength.
Solution Approach 2:
Different parts of the crate are given different structural properties: corner sections have upwardly protruding locking projections for form-fitting engagement with recesses in stacked crates, while longitudinal edge sections have inwardly folded edge flaps with bearing surfaces parallel to the floor for load distribution. This local differentiation resolves the contradiction by providing both stacking capability and strength in appropriate locations.
2Adaptability or versatility
If corner projections are formed by extensions over walls with connecting tabs, then stackability is achieved, but the simple wall thickness results in comparatively low strength
Solution Approach 1:
The corner sections with locking projections are nested within the overall crate structure, with the projections extending upward from the corner areas. The base sections with recesses receive these projections, creating a nested stacking arrangement that provides both stackability and structural integrity through the form-fitting engagement.
3Reliability
If lugs projecting over bearing surfaces are provided to hold crate bottom, then stacking protection in one direction is achieved, but protection is only possible in one direction and inclined walls are required
Solution Approach 1:
The corner sections are positioned asymmetrically at the corners of the crate, with upwardly protruding locking projections that engage with corresponding recesses in the base of stacked crates. This asymmetric corner positioning provides stability and protection in multiple directions simultaneously, eliminating the need for inclined walls and single-direction protection.
4Stability of the object's composition
If floor recesses are provided for corner extensions, then form-fitting stacking is achieved, but the wall recess protruding freely on both sides of jacket corner leads to impractical floor corners
Solution Approach 1:
The base is provided with recesses in specific locations corresponding to the corner sections, creating localized form-fitting engagement zones. These recesses are positioned to receive the upwardly protruding locking projections from corner sections, providing stable stacking while maintaining practical floor corner geometry that is easy to manufacture.
Data Source
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AI summary
The invention relates to a crate in the form of a flap-adhered box made of cardboard, comprising a base (1) and a casing (2) which projects from the base (1), said casing forming upper longitudinal edge portions reinforced by edge flaps (10), which are folded inwards between the casing corners. The aim of the invention is to achieve advantageous structural conditions. This is achieved in that the longitudinal edge portions which are reinforced by the edge flaps (10) folded inwards have corner portions (13) which project upwards and between which the edge flaps (10) are bent back towards the casing (2) about two crease lines (16) that are set back relative to the folding lines (15) of the corner portions (13), thereby forming a support surface (17), which is parallel to the base, between the crease lines (16); the base (1) is provided with recesses (19) which are adapted to the cross-sectional shape of the projecting corner portions (13) in the region of the casing corners; and the casing (2) is recessed in the region of the base recesses (19) at a depth which corresponds to the projection of the corner portions (13) of the reinforced longitudinal edge portions.