Dual Side Seam Corrugated Case Blank Design
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Solution Overview
Problem
The existing Regular Slotted Container (RSC) cases made from corrugated fibreboard are inefficient in shipping due to their asymmetric shape, leading to unstable stacking and increased shipping costs, and often have inaccuracies in alignment and gluing, resulting in improper construction and erection issues.
Innovation Solution
A new blank design, the Dual Side Seam-Regular Slotted Container (DSS-RSC) blank, which is cheaper to manufacture and provides equivalent or better strength than RSCs, featuring a unique configuration of panels that can be efficiently formed into cases at customer premises using a specific system involving die cutting and folding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If RSC cases are made with asymmetric shape, then they can be formed from conventional blanks, but stacking stability deteriorates and shipping efficiency decreases
Solution Approach 1:
The patent applies asymmetry principle by designing the blank with asymmetric panel configurations (different end panel lengths, offset side seams) that transform the symmetric RSC structure into an asymmetric knockdown form. This asymmetric blank design enables stable stacking in collapsed state while maintaining ease of manufacture through conventional corrugated board materials and standard folding mechanisms.
2Ease of manufacture
If conventional RSC blanks are used, then manufacturing process is simple, but alignment accuracy and construction precision deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-configuring the blank with precisely positioned fold lines, pre-glued joints, and predetermined panel orientations during blank manufacturing. This preliminary preparation ensures that when the blank is assembled into the final RSC form, the panels align accurately and construct precisely without requiring complex adjustment mechanisms during final assembly.
3Strength
If more corrugated material is used to enhance strength, then case strength improves, but material wastage increases
Solution Approach 1:
The patent applies parameter changes by optimizing the blank dimensions, panel thicknesses, and material distribution to achieve the minimum required strength while minimizing material usage. The asymmetric blank design allows for strategic placement of thicker or reinforced panels only where structurally necessary, rather than uniformly increasing material throughout the entire case structure.
Data Source
AI summary
A case is disclosed that is made from a corrugated material and has a generally flat transversely extending base panel and first and second transversely extending, generally parallel, side wall panels upstanding from, and being oriented generally orthogonal to, the base panel. First and third end wall panels meet at a first vertically extending seam extending upwards from one end of the base panel and second and fourth end wall panels meet at a second vertically extending seam extending upwards from an opposite end of the base panel. A blank for forming such a case is also disclosed. A method comprises forming a sheet of corrugated fiberboard; operating a die cutting apparatus to form a generally flat case blank from the sheet of corrugated fiberboard at a first location; transporting the flat case blank to a second location; operating a case forming apparatus at the second location to fold the case blank to form the case; after the case has been formed by the case forming apparatus, operating a loading apparatus to load at least one item into the case; and sealing opposed top panels.