Cross-Laminated Corrugated Container Sidewall Bulge Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional corrugated paperboard containers for bulk fluid storage are prone to bulging sidewalls, difficult to set up, and costly, making them inefficient for shipping and handling, especially when trying to fit multiple containers on a pallet without damage or contamination.
Innovation Solution
A reinforced cross-laminated corrugated paperboard container with interlocking full bottom flaps, pre-broken scores, and reinforcing tape, designed to minimize bulging and ease assembly, allowing for efficient stacking and containment of fluid products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional corrugated paperboard containers are used for fluid storage, then they are less costly to manufacture and can be collapsed for compact storage, but the sidewalls bulge outwardly when filled with fluid product making them difficult to set up and prone to damage
Solution Approach 1:
The patent applies composite materials by laminating a corrugated paperboard container with a plastic film (such as polyethylene) to create a hybrid structure. The plastic film acts as a reinforcing layer that prevents sidewall bulging while maintaining the cost-effectiveness and collapsibility of the paperboard container. This composite construction resolves the contradiction by providing the structural integrity of metal drums at a fraction of the cost.
Solution Approach 2:
The patent uses a flexible plastic film (thin film) as a reinforcing shell that is laminated to the corrugated paperboard container walls. This thin film acts as a protective barrier that prevents the sidewalls from bulging outward under fluid pressure, while the film itself remains flexible enough to allow the container to be collapsed for compact storage and transport.
2Reliability
If conventional corrugated paperboard containers are made stronger to hold fluid material, then they can contain fluid products, but they become difficult to set up from a flattened condition and expensive to manufacture
Solution Approach 1:
The plastic film laminated to the corrugated paperboard creates a composite structure that maintains strength for fluid containment while preserving the ease of setup. The plastic film is applied to pre-formed container shapes, allowing the container to be collapsed flat for storage and then easily erected by simply opening the collapsed structure, without requiring complex assembly operations.
Solution Approach 2:
The plastic film is laminated to the container walls in advance during manufacturing, creating a pre-reinforced structure. This preliminary reinforcement ensures that when the container is collapsed and later set up, it maintains its structural integrity and can be easily erected without requiring additional strengthening operations or complex assembly steps.
3Productivity
If conventional corrugated paperboard containers are designed to fit efficiently on pallets, then they improve handling and storage efficiency, but the sidewalls may extend beyond the pallet perimeter and be subject to damage
Solution Approach 1:
The plastic film laminated to the container walls acts as a protective shell that prevents damage to the container corners and edges. When four containers are arranged on a pallet, the film reinforces the sidewalls and corners, protecting them from impact and damage during handling and storage, while still allowing the containers to fit efficiently within the pallet perimeter.
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 stacked container that prevents sidewall bulging and contamination, enabling efficient palletization and reuse/recycling, while maintaining structural integrity for fluid products.
Implementation Method 1
cross lamination of a corrugated inner liner and an outer component
Implementation Method 2
The cross lamination of the inner liner and outer component, together with the cross-hatch pattern created by the direction of the reinforcing tape or strands, fortifies the sidewalls against bulge
Implementation Method 3
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 in the liner and in the outer component
Implementation Method 4
pre-breaking of the scores in the liner before lamination with the outer component
Implementation Method 5
the pre-breaking of the scores in the liner before it is laminated to the outer component... provides ease of fabrication and makes it easier for the end-user to open up the container from a knocked down condition
Data Source
AI summary
A reinforced cross laminated corrugated paperboard bulk container has an outer component with corrugations running in a first direction, and an inner liner laminated to the outer component, with the liner having corrugations extending perpendicular to the corrugations in the outer component. Reinforcing strands are in both the liner and the outer component, extending perpendicular to the respective corrugations thereof. Interlocking top flanges are on the top edges of the outer component, and interlocking bottom flanges are on the bottom edges thereof. The interlocking bottom flanges include a chevron shaped locking slot in one flange and a locking tab on an opposed bottom flange. Folds extend across the bottom flanges to enable them to deflect and slide relative to one another during set up of the container. Vertical scores in the liner are pre-broken prior to laminating it to the outer component.