Double-Walled Cardboard Container with Nested Shells
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Solution Overview
Problem
The manufacturing process for containers made of cardboard or paperboard is complicated and costly due to the need to laminate multiple layers of sheet material, which is not necessary for achieving improved strength properties.
Innovation Solution
A single-piece container design featuring an outer shell and an inner shell connected along a foldline, where the inner shell sidewall panels are in face-to-face contact with the outer shell sidewall panels, providing a two-ply wall thickness without the need for lamination, and incorporating reinforcement flaps for enhanced strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple layers of sheet material are laminated together, then the container strength is improved, but the manufacturing process becomes complicated and costly
Solution Approach 1:
The container is divided into an outer shell and an inner shell that are separately formed from a single sheet material and then assembled together. This segmentation allows each shell to be manufactured independently using simple processes, while the combination provides enhanced strength without requiring complex lamination of multiple layers.
Solution Approach 2:
The inner shell is nested within the outer shell, with the inner shell positioned inside the container formed by the outer shell. This nested configuration provides reinforced wall structure and improved strength, while both shells can be manufactured using simple, non-laminating processes.
2Strength
If multiple layers of sheet material are laminated together, then the container can hold heavier products, but additional manufacturing stages are added
Solution Approach 1:
The container structure is segmented into outer and inner shells that are manufactured separately and then assembled. This allows each shell to be produced efficiently using simple forming processes, and the assembly step provides the load-bearing enhancement without requiring time-consuming lamination stages.
Solution Approach 2:
The outer and inner shells are pre-formed as separate components before final assembly. This preliminary formation of individual shells using simple processes allows for efficient manufacturing, and the subsequent assembly provides the enhanced load-bearing capacity without adding complex lamination steps.
Data Source
AI summary
A single piece container (200) made from cardboard, paperboard or other lightweight foldable sheet material is provided. The container (200) includes an outer shell and an inner shell. The outer shell has first and second ends (202, 204), and includes a plurality of outer shell sidewall panels (3, 5, 7, 9) hingedly connected to one other about respective outer shell sidewall foldlines. The outer shell sidewall panels (3, 5, 7, 9) extend between the first and second ends (202, 204) of the outer shell. At least the second end of the outer shell is a closed end. The inner shell includes a plurality of inner shell sidewall panels hingedly connected to one other about respective inner shell sidewall foldlines. The inner shell is integrally connected to the outer shell along a foldline. Each one of the inner shell sidewall panels is in face-to-face contact with the inner surface of a respective one of the outer shell sidewall panels (3, 5, 7, 9).