Cross-Laminated Corrugated Bulk Container Bulging Prevention
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Solution Overview
Problem
Conventional corrugated paperboard containers for bulk fluid storage are prone to bulging, difficult to set up, and expensive, making them unsuitable for efficient palletization and reuse/recycling, especially for 20 to 80 gallon capacities.
Innovation Solution
A reinforced cross-laminated corrugated paperboard container with interlocking full bottom flaps, pre-broken scores, and reinforcing tape, allowing for easier fabrication, setup, and secure containment, while fitting four containers on a pallet without bulging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional corrugated paperboard containers are used for bulk fluid storage, then manufacturing cost is reduced, but sidewalls bulge outwardly and the container becomes difficult to set up
Solution Approach 1:
The patent applies composite materials by laminating an inner corrugated liner to an outer flat component, creating a multi-layer structure that combines the cost-effectiveness of corrugated material with the structural rigidity of the laminated composite. This cross-laminated construction prevents sidewall bulging while maintaining ease of manufacture at lower cost than metal or fibre drums.
Solution Approach 2:
The patent applies local quality by placing reinforcing tape at specific locations where the container walls are most vulnerable to bulging, rather than uniformly strengthening the entire structure. The tape is positioned at strategic points to provide localized reinforcement that prevents sidewall deformation while keeping overall manufacturing costs low.
2Ease of manufacture
If conventional corrugated paperboard containers are used for bulk fluid storage, then manufacturing cost is reduced, but the container becomes difficult to set up from flattened condition
Solution Approach 1:
The patent applies preliminary action by pre-breaking the scores in the inner liner before lamination. This preliminary modification of the score lines makes the container easier to expand from its flattened condition during setup, while the cross-laminated structure maintains the cost advantages of conventional corrugated construction.
3Strength
If cylindrical drums are used for bulk storage, then strength and durability are improved, but the container cannot efficiently fit on pallets due to circular footprint leaving void spaces
Solution Approach 1:
The patent applies the inversion principle by transitioning from a cylindrical shape (which naturally fits its own geometry) to a rectangular prism shape. This geometric inversion allows the container to efficiently fit within standard rectangular pallet configurations, eliminating void spaces and improving palletization density while maintaining the strength and durability needed for bulk fluid storage.
4Productivity
If square or rectangular containers are sized to fit pallets, then palletization efficiency is improved, but bulging sidewalls cause the container to extend beyond pallet perimeter and be subject to damage
Solution Approach 1:
The patent applies composite materials through cross-lamination of the inner corrugated liner to the outer flat component, creating a rigid multi-layer structure that prevents sidewall bulging. This reinforced composite construction allows the container to maintain its rectangular shape within pallet boundaries without extending beyond the perimeter, thus protecting it from damage while achieving efficient palletization.
Solution Approach 2:
The patent applies local quality by using reinforcing tape at specific strategic locations on the container walls to prevent bulging at critical points. This targeted reinforcement ensures the sidewalls remain within pallet boundaries during storage and handling, preventing damage while maintaining the dimensions needed for efficient palletization.
5Adaptability or versatility
If flexible bag liner is used in conventional containers, then containment is provided, but the liner may be damaged by elements of the container protruding into the interior
Solution Approach 1:
The patent applies composite materials by using a cross-laminated structure where the inner corrugated liner is bonded to an outer flat component. This reinforced composite construction eliminates protruding elements that would damage the liner, as the laminated structure provides a smooth, stable interior surface that protects the flexible bag liner while maintaining effective containment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a cost-effective, easily assembled, and securely containing bulk fluid storage solution that prevents bulging and ensures efficient palletization, reducing material costs and handling risks.
Implementation Method 1
cross lamination of a corrugated inner liner and an outer component
Implementation Method 2
use of re-enforcing tape such as Sesame Tape or a comparable re-enforcing strand in the liner and in the outer component, with the reinforcing tape extending perpendicular to the respective corrugations
Implementation Method 3
pre-breaking of the scores in the liner before lamination with the outer component
Data Source
AI summary
A reinforced cross laminated corrugated paperboard bulk container has an outer component and an inner liner laminated to the outer component with the liner having corrugations extending perpendicular to the corrugations in the outer component. The bottom edges of the sidewalls include a first pair of flaps and a second pair of flaps each of which foldably extend outwardly therefrom and wherein each of the second pair of flaps having a pair of spaced apart triangularly shaped slots formed therein and wherein each of the first pair of flaps includes a pair of locking tabs formed on opposed end of the respective first pair of flaps which are engaged with the slots on the second pair of the flaps to securely close the bottom of the container. Vertical scores in the liner are pre-broken prior to laminating it to the outer component.