Double-Walled Cardboard Container With Nested Inner Liner

Solution Overview

Problem

Existing cardboard and paperboard containers require laminating multiple layers of sheet material to achieve strength, complicating the manufacturing process and increasing costs.

Innovation Solution

A single-piece container design featuring a combination of outer and inner sidewall panels with specific foldlines and connections, allowing for a single-piece construction that provides both internal support and reinforcement without the need for lamination, using a set of inner sidewall panels to reduce internal space and reinforce the outer shell.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If multiple layers of sheet material are laminated together to create a container, then the container strength and ability to hold heavier products is improved, but the manufacturing process complexity and cost increase

Engineering Contradiction:

Improvecontainer strengthVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The container is divided into an outer shell and an inner liner, each made from separate single-layer sheet materials. The outer shell comprises sidewall panels that can be segmented and folded, while the inner liner is a separate component. This segmentation allows each layer to be manufactured independently using simple folding processes rather than requiring lamination of multiple layers, thus maintaining container strength while simplifying the manufacturing process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The inner liner is nested within the outer shell, with the inner liner positioned inside the container cavity defined by the outer shell. The inner liner comprises inner sidewall panels that are inserted into or formed within the outer shell structure. This nested configuration provides structural reinforcement and product support without requiring the complex lamination process, as the inner liner is a separate component placed within the outer shell.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Strength

If multiple layers of sheet material are laminated together to create a container, then the container strength and ability to hold heavier products is improved, but the manufacturing cost increases

Engineering Contradiction:

Improvecontainer strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The container is divided into an outer shell and an inner liner, each made from separate single-layer sheet materials. The outer shell comprises sidewall panels that can be segmented and folded, while the inner liner is a separate component. This segmentation allows each layer to be manufactured independently using simple folding processes rather than requiring lamination of multiple layers, thus maintaining container strength while simplifying the manufacturing process and reducing costs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The inner liner is designed to be self-supporting and to provide product support through its own structural configuration rather than requiring bonded integration with the outer shell. The inner sidewall panels are configured to automatically provide reinforcement and product support when inserted into the outer shell, eliminating the need for complex lamination bonding processes and reducing manufacturing costs.

Inventive Principle:

Principle #25Self-service

3Strength

If inner sidewall panels are added to reduce internal space and reinforce the outer shell, then product support and container strength are improved, but the device complexity increases

Engineering Contradiction:

Improvecontainer strengthVSAvoidcontainer structure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The container is divided into an outer shell and an inner liner, each made from separate single-layer sheet materials. The outer shell comprises sidewall panels that can be segmented and folded, while the inner liner is a separate component. This segmentation allows each layer to be manufactured independently using simple folding processes rather than requiring lamination of multiple layers, thus maintaining container strength while simplifying the manufacturing process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The inner liner serves multiple functions simultaneously: it provides structural reinforcement to the outer shell, creates an inner cavity for product placement, reduces the effective internal space to better fit the product contours, and provides product support through its configured sidewall panels. This multi-functionality is achieved through a single integrated component design rather than requiring multiple separate structural elements, thus not significantly increasing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12017825B2Double-walled container

Publication Date: 2024.06.25 MULTI PACKAGING SOLUTIONS UK LTD

AI summary

A single piece container made of cardboard, paperboard or other flexible sheet material which provides improved strength properties, but without the need to laminate layers of sheet material together by having an outer shell comprising sidewall panels (3, 5, 7, 9) and a set of inner sidewall panels (11, 13, 15, 17) connected to the outer shell at foldlines. The set of inner sidewall panels includes a first inner sidewall panel in facing relationship with the inner surface of a first outer shell sidewall panel and integrally connected to one of the outer shell sidewall panels along a foldline, and a first set of further inner sidewall panels integrally connected to the first inner sidewall panel along a foldline, the sidewall panels of the set of further inner sidewall panels being hingedly connected to one another about respective foldlines. The set of inner sidewall panels also includes a second set of further inner sidewall panels integrally connected to the first inner sidewall panel along a foldline, the sidewall panels of the second set of further inner sidewall panels being hingedly connected to one another about respective foldlines.