Curved-Corner Corrugated Tray for Stable Bottle Holding
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Solution Overview
Problem
Existing trays and cartons fail to effectively conform to the shape of articles, leading to movement and shifting during production, storage, and distribution, particularly for containers and bottles.
Innovation Solution
A tray design featuring a fluted layer between two plies, with corner panels folding along the flute direction to create curved corners that conform to the shape of the articles, providing structural support and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If existing trays use flat panels without fluted layers, then manufacturing is simpler, but the trays cannot conform to the shape of articles causing movement and shifting
Solution Approach 1:
The tray uses a composite structure with a fluted layer positioned between two plies, creating a multi-layer construction that enables the tray to conform to curved surfaces of articles while maintaining structural integrity. The fluted layer acts as a cushioning element that allows the tray to adapt to various article shapes without requiring complex molding processes.
Solution Approach 2:
The fluted layer changes the physical parameters of the tray by introducing a corrugated structure that provides both rigidity and flexibility. This structural modification allows the tray to deform and conform to article shapes while maintaining sufficient strength to hold articles securely during production, storage, and distribution.
2Reliability
If trays use straight edges and corners, then manufacturing is easier, but articles move and shift during handling
Solution Approach 1:
The tray incorporates curved corners instead of sharp right angles, with the corner panels forming arcs that match the curvature of typical article corners. This curvature allows the tray to cradle articles securely, preventing movement and shifting during handling while the curves can be easily formed through standard folding and joining processes.
Solution Approach 2:
The tray applies different geometric properties to different regions: straight panels for the main body to maintain manufacturing simplicity, and curved corners specifically at the corners where articles typically contact the tray. This localized application of curvature provides stability where needed without complicating the overall manufacturing process.
3Strength
If trays are made from single-layer material, then production is faster, but load-bearing capacity is insufficient
Solution Approach 1:
The tray is constructed from multiple plies with a fluted layer between them, creating a composite structure that significantly enhances load-bearing capacity. The layered construction with the fluted core provides both strength and cushioning, allowing the tray to support heavier loads while the components can be manufactured separately and assembled efficiently.
Solution Approach 2:
The tray structure is divided into distinct segments: outer plies for strength and a fluted intermediate layer for cushioning and conformability. This segmentation allows each layer to be optimized for its specific function and manufactured through streamlined processes, with the layers then joined together to create the final high-strength tray.
Data Source
AI summary
A tray for holding articles includes a plurality of panels extending at least partially around an interior of the tray, the tray having a bottom panel, at least one side panel, at least one end panel, and at least one corner panel forming a curved corner between the at least one side panel and the at least one end panel. The tray includes a first ply, a second ply, and a fluted layer positioned between the first ply and the second ply, the fluted layer arranged along a flute direction, the curved corner extending upwardly from the bottom panel along the flute direction.