Cardboard Crate Reinforcement via Nested Flap and Inner Layer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Cardboard crates erected from blanks require larger formats and increased waste due to the need for extended edge flaps to support additional loads, which also necessitate larger cutting tools, compromising load-bearing capacity and stackability.
Innovation Solution
Incorporating a separate cardboard layer inside the crate with a plug-in attachment system that fits into a receiving pocket between the jacket and the blank, providing reinforcement and support without enlarging the crate format, and using snap-in projections or adhesive areas for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the edge flaps are extended to provide sufficient load-bearing capacity for hand-erected trays, then the load-bearing capacity is improved, but the cardboard size and waste increase
Solution Approach 1:
The flap section is nested within the space between the outer wall and the inner cardboard layer, utilizing the existing structural volume rather than extending outward. This allows the flap to achieve sufficient load-bearing capacity through strategic placement and support from the inner layer without requiring additional cardboard material.
Solution Approach 2:
The solution moves from a two-dimensional extension of the flap in the lateral direction to a three-dimensional utilization of the vertical space between the outer and inner cardboard layers. By bending the flap section against the inner layer, the design exploits the third dimension (depth/thickness) to achieve structural reinforcement without increasing the lateral footprint.
2Force
If the edge flaps are extended to support additional loads, then the load transfer capability is improved, but the cutting tool size and complexity increase
Solution Approach 1:
The extended flap section is nested within the existing cardboard structure between the outer wall and inner layer, utilizing already-present material rather than requiring larger blank sizes. This eliminates the need for larger cutting tools while achieving the required load transfer capability.
3Strength
If a separate cardboard layer is added inside the casing for reinforcement, then the load-bearing capacity is improved, but the device complexity increases
Solution Approach 1:
The inner cardboard layer is integrated with the outer wall through the plug-in attachment mechanism, where the bent-back flap section connects the two layers. This merging creates a composite structure that enhances load-bearing capacity while maintaining manufacturing simplicity, as the additional layer serves multiple functions (reinforcement, flap support, and structural integration).
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A cardboard tray made from a manually erectable blank is described, wherein the erected blank forms a base (1) and a shell (2) with stacking lugs (13) projecting vertically at the shell corners and with reinforced upper longitudinal edge sections between the stacking lugs (13) in the form of inwardly folded edge flaps (7). These flaps are folded back against the shell (2) by two crease lines (12) to form a base-parallel support rib (15) and are fixed against the shell (2) by the folded-back flap section (10). To achieve advantageous design conditions, it is proposed that the folded-back flap section (10) of the reinforced longitudinal edge sections has a slot (20) that engages in a receiving pocket (19) between the shell (2) and a cardboard layer (16) provided on the inside of the shell and held against the shell (2), which is separate from the blank.