Flat Blank Carton With Integral Locking Flaps
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Solution Overview
Problem
Pre-glued carton sleeves for product packaging are more expensive to produce and require additional materials and equipment, resulting in increased costs and space requirements for storage and transportation due to their thickness and need for gluing and cases.
Innovation Solution
A flat blank carton design with integrally formed locking mechanisms and gussets that can be folded and locked together during the packaging process, eliminating the need for pre-gluing and cases, allowing for efficient stacking and transportation as a single sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pre-glued carton sleeves are used for product packaging, then product packaging can be achieved, but production costs increase and additional materials and equipment are required
Solution Approach 1:
The locking mechanisms are integrally formed with the carton blank itself, merging the structural support function and the locking function into a single component. This eliminates the need for separate glue application equipment and pre-formed sleeves, directly reducing production costs and equipment requirements while maintaining packaging effectiveness
Solution Approach 2:
The carton blank's side flaps automatically lock together through integrally formed locking mechanisms during the folding process, without requiring external glue application or additional assembly equipment. The structure serves its own locking function, eliminating the need for separate gluing operations and reducing equipment complexity
2Volume of moving object
If pre-glued carton sleeves are used, then product packaging is achieved, but space requirements for storage and transportation increase due to thickness and need for cases
Solution Approach 1:
The carton blank is designed with distinct folding zones and locking zones that allow it to be compressed into a flat, space-efficient state for storage and transportation, then expanded into its functional three-dimensional form during use. The integral locking mechanisms enable this transformation without requiring protective cases
Solution Approach 2:
The carton transitions from a three-dimensional pre-glued sleeve form to a two-dimensional flat blank form for storage and transportation. The integral locking mechanisms maintain structural integrity during this dimensional transition, eliminating the need for protective cases and significantly reducing storage volume
Data Source
AI summary
A flat blank carton is provided for packaging articles or products. The flat blank carton includes a base, a top, and a rear panel, hingedly connected to one another, and pairs of upper and lower side flaps hingedly attached to the top and base panels, respectively. The upper and lower side flaps include locking projections and corresponding locking recesses that are brought into mating, locking engagement as the top panel is folded over the base panel. After loading with products, the front end flaps of the cartons can be sealed to close the cartons.