Curved-Edge Panel Interlocking for Secure Carton Assembly

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing panel interlocking devices for cartons are inefficient in securing overlapping panels and often require excessive material usage, leading to wastage and reduced structural integrity.

Innovation Solution

A panel interlocking device featuring a male tab with a concavely curved side edge and a female tab with opposing side edges also concavely curved along their length, allowing for secure engagement and reduced material usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional locking tabs with straight edges are used, then the interlocking mechanism is simple to manufacture, but the panel security is insufficient and material wastage increases

Engineering Contradiction:

Improvepanel securityVSAvoidmaterial wastage

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent applies curvature to the edges of the locking and retaining tabs, replacing traditional straight edges with curved edges. This curvature allows the tabs to engage more effectively with complementary shapes, enhancing panel security while reducing the amount of material needed for the interlocking mechanism.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Strength

If excessive material is used for panel interlocking, then structural integrity is maintained, but material wastage increases and cost rises

Engineering Contradiction:

Improvestructural integrityVSAvoidmaterial wastage

Core Design Contradiction:

StrengthVSLoss of substance

Solution Approach 1:

The patent applies local quality by concentrating material strategically at the engagement points of the tabs rather than using uniform thickness throughout. The curved edges are positioned to provide localized strength where needed for interlocking, while reducing material in areas where it is not required, thus maintaining structural integrity with minimal material.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If simple interlocking mechanisms are used, then manufacturing is easier, but panel security is insufficient

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidpanel security

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The curved edges on the locking and retaining tabs provide enhanced engagement and panel security while maintaining manufacturing simplicity. The curvature is achieved through standard cutting or forming processes, and the complementary curved shapes work together to create a secure interlock without requiring complex mechanisms.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentEP3924265B1Panel interlocking device

Publication Date: 2025.09.10 WESTROCK PACKAGING SYSTEMS LLC

Figure 1
Figure 2~3C
Figure 3

AI summary

Aspects of the disclosure relate to a panel interlocking device, a carton, and a blank for forming the carton. The carton blank incorporating a panel interlocking device for securing together a first and a second panel in overlapping relationship. The panel interlocking device comprises a locking tab struck from the first panel, and a retaining tab defining a locking aperture struck from the second panel. In use the retaining tab is displaced out of the plane of the second panel to receive said locking tab through the locking aperture to be engaged therewith. The retaining tab has opposing side edges each concavely curved as viewed from the outside of the retaining tab.