Display Carton with Overlapping Rear Wall and Rolled Front Edge
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Solution Overview
Problem
Display cartons used for packaging and displaying multiple units of products, such as consumable cleaning containers, face challenges in withstanding weight when stacked and providing adequate visibility and information to consumers, while maintaining structural integrity and aesthetic appeal.
Innovation Solution
A display carton design featuring a bottom wall, side walls, a rear wall formed by overlapping folded portions, and a front wall with a rolled upper edge, allowing for easy assembly and visibility through cutouts, and utilizing a carton blank with scored lines for efficient folding, either manually or by machine, to minimize material waste and enhance visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rear wall is formed by overlapping and adhering folded portions of side walls, then assembly efficiency is improved and structural integrity is enhanced, but manufacturing complexity increases
Solution Approach 1:
The side walls are designed with fold lines that divide them into multiple sections, allowing the rear wall to be formed by folding and overlapping these segmented portions. This segmentation enables automated folding processes while maintaining structural integrity through the overlapping adhered sections.
Solution Approach 2:
The carton blank is pre-scored and pre-folded along predetermined lines before assembly. The side walls are pre-folded to create the rear wall sections that will overlap and adhere together, reducing manual effort during final assembly and improving production efficiency.
2Loss of information
If cutouts are provided in the upper edge of the rear wall for product visibility, then consumer information access is improved, but structural strength is reduced
Solution Approach 1:
The rear wall is designed with varying properties: the majority of the wall maintains full thickness and strength for structural support, while localized cutout sections are provided to allow product visibility. This local modification provides information access without compromising the overall structural integrity of the carton.
3Shape
If the front wall is formed with multiple panels defining a rolled upper edge, then aesthetic appearance is improved, but manufacturing complexity increases
Solution Approach 1:
The front wall panels are folded and rolled to create a curved, rolled upper edge instead of a flat or sharp edge. This curvature provides an aesthetically pleasing appearance and is achieved through predetermined fold lines in the blank that guide the rolling process during assembly.
Solution Approach 2:
The front wall is divided into multiple panels that are folded and rolled in sequence. This segmentation allows the complex rolled edge to be formed through a series of simpler folding operations rather than a single complex process, making it more manufacturable.
4Strength
If the carton is designed to withstand stacked weights, then structural integrity is improved, but material usage increases
Solution Approach 1:
The rear wall is formed by overlapping portions from both side walls and adhering them together, creating a three-dimensional reinforced structure. This dimensional approach distributes the stacked weight across multiple adhered sections rather than requiring a single thick wall, reducing overall material usage while maintaining strength.
Solution Approach 2:
The overlapping and adhering of folded portions creates a composite structure where multiple layers of cardboard work together to provide enhanced strength. This composite construction achieves the required load-bearing capacity with less material than a solid thick wall would require.
Data Source
AI summary
A display carton includes a bottom wall, a first side wall, a second side wall, a front wall with a rolled upper edge, and a rear wall, with the rear wall formed by overlapping, folded panels that are adhered together at the overlap. The display carton can be assembled from a blank, in part by folding panels together to partially overlap the panels, and adhering the panels together.