Cardboard Crate Edge Flap Reinforcement for Bulging Resistance
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Solution Overview
Problem
Stackable cardboard crates face issues with lateral bulging, particularly under transverse forces, due to the lack of effective shear-resistant connections between adjacent wall parts, which limits their strength and resistance to bulging despite material reinforcement.
Innovation Solution
The edge flaps of the crate are bent back and glued to the jacket, forming a support web that connects to a triangular support section, enhancing the bulging resistance through additional cardboard layers and improved flexural rigidity, either directly or via a connecting web, to distribute loads effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If edge flaps are bent back to form support ribs with triangular cross-section, then load-bearing capacity is improved, but lateral bulging resistance deteriorates under shear force
Solution Approach 1:
The patent combines multiple cardboard layers (edge flap + folded flap + connecting web) to create a composite reinforcement structure. This composite construction increases both load-bearing capacity and bulging resistance by distributing stresses across multiple bonded layers, resolving the contradiction between strength improvement and bulging prevention.
Solution Approach 2:
The folded flap extends in a third dimension perpendicular to the support rib, creating a multi-dimensional reinforcement structure. This additional dimensional element (the folded flap protruding from the support rib) provides extra resistance to lateral bulging while maintaining the load-bearing function of the support rib.
2Strength
If folded flap is attached directly to inclined support rib, then bending stiffness is improved, but manufacturing complexity increases
Solution Approach 1:
The folded flap is formed from the same cardboard material as the support rib itself, using the existing material rather than adding separate reinforcement elements. This self-service approach increases bending stiffness while minimizing manufacturing complexity, as the reinforcement is created from the base material through folding and gluing operations.
3Stability of the object's composition
If connecting web is introduced to attach folded flap, then structural stability is improved, but ease of manufacture deteriorates
Solution Approach 1:
The connecting web merges the folded flap with the support rib structure, creating an integrated reinforcement system. This combining of elements improves structural stability by ensuring rigid connection between components, while the web is designed to be formed from the same cardboard stock, maintaining ease of manufacture through unified material processing.
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 that are reinforced by edge flaps (6) folded inwards between the casing corners and have corner portions (8) which protrude upward and correspond to base recesses (19) and between which a support portion (9) of the the edge flaps (6) is bent back towards the casing (2) about two crease lines (11) that are set back relative to the folding lines (10) of the corner portions (8), thereby forming a support web (12) which is parallel to the base. The aim of the invention is to improve the bending stiffness of the casing. This is achieved in that the edge flaps (6) bent back towards the casing (2) are provided with a folding flap (17), which is bent back towards the support web (12) about a folding line (16) and which is adhered to the casing (2), on the flap face facing the casing (2).