Expandable Carton With Detachable End Sections
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Solution Overview
Problem
Existing packaging solutions fail to provide an expandable structure that can increase capacity while maintaining material efficiency, strength, and compatibility with existing automatic machines, especially for accommodating additional items like ice during outdoor events.
Innovation Solution
An expandable carton design featuring hinged walls and detachable expansion end sections connected by a connecting member, allowing for increased capacity by separating and raising sections to form extensions, with minimal material usage and compatibility with existing machinery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the carton is designed to be expandable to accommodate additional items, then the capacity and versatility are improved, but the structural complexity and material usage increase
Solution Approach 1:
The end closure flap is divided into multiple detachable sections (first section and second section) that can be separated from each other. This segmentation allows the carton to expand its capacity by creating additional space while maintaining a relatively simple overall structure. The sections are connected through detachable connections that enable easy separation and reattachment.
Solution Approach 2:
The detachable end sections are designed to nest within each other when attached, forming a compact closed structure. When detached, they create expanded space. This nesting approach allows the expandable feature to be integrated without significantly increasing the footprint or structural complexity of the carton in its closed state.
2Loss of substance
If the carton uses minimal material for cost and environmental considerations, then material efficiency is improved, but the strength and durability may deteriorate
Solution Approach 1:
Gusset folds are pre-formed at specific locations (such as at the corners and edges of the end closure flaps) during the carton manufacturing process. These pre-formed gusset folds create reinforced zones that increase structural strength and durability without requiring additional material. The gusset folds are integrated into the existing flap structure, maintaining material efficiency while providing enhanced strength where needed.
3Ease of manufacture
If the carton is designed for easy assembly on existing automatic machines, then ease of manufacture is improved, but the functionality and adaptability may be limited
Solution Approach 1:
The detachable end sections are designed with self-aligning features and intuitive connection mechanisms that allow them to be attached and detached without complex tooling or specialized machinery. The sections can be easily manipulated by the machine's existing components, allowing the expandable functionality to be integrated into standard carton assembly processes without requiring significant modifications to existing automatic machines.
Data Source
AI summary
Aspects of the invention relate to an expandable carton (90) which can be opened from a closed state having a first capacity, into an opened state having a second, greater capacity such that ice or other additional articles can be loaded into the expanded carton along with the original articles housed therein. The carton (90) comprises: a top wall (12), a bottom wall (16), a first side wall (14), and a second side wall (18) hingedly connected to one another to form a tubular structure. The carton (90) additionally comprises a first end wall (22a, 24a, 26a, 28a) and a second end wall (22b, 24b, 26b, 28b), each of said end walls (22a, 24a, 26a, 28a; 22b, 24b, 26b, 28b) for enclosing an open end of the tubular structure of the carton.