Bag-in-Box Blanks with Interlocking Flaps and Cross-Corrugation

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Solution Overview

Problem

Existing bag-in-box systems face challenges with poor lateral rigidity, limited stackability, complex and costly fabrication processes, and the presence of sharp edges or corners that can damage bags.

Innovation Solution

The development of box blanks with interlocking portions and flaps, featuring cross-corrugation on three sides, which simplifies the fabrication process, enhances lateral stability, and eliminates internal edges or corners.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If adhesive is applied to adjacent flaps and pressing apparatus is used to induce adhesion, then box fabrication is achieved, but the fabrication process becomes complex, time-consuming and costly

Engineering Contradiction:

Improvefabrication process simplicityVSAvoidfabrication apparatus complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The box blank is designed with self-locking features where flaps interlock with each other through geometric constraints and friction, eliminating the need for external adhesive application and pressing apparatus. The structure itself provides the joining mechanism through its configuration

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The invention removes the adhesive and pressing apparatus components from the fabrication process, replacing them with a purely mechanical interlocking design that can be assembled without additional materials or equipment

Inventive Principle:

Principle #2Taking out (Extraction)

2Strength

If conventional box construction is used, then box fabrication is achieved, but lateral rigidity and stackability are poor

Engineering Contradiction:

Improvelateral rigidityVSAvoidfabrication complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The box blank incorporates three-dimensional interlocking features and angled flap configurations that create lateral bracing when assembled, transforming a simple two-dimensional folding process into a three-dimensional self-reinforcing structure that provides enhanced rigidity

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The design combines multiple layers of corrugated cardboard with interlocking geometries to create a composite structure where the layers work together to provide enhanced lateral strength and rigidity beyond what single-layer construction could achieve

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If conventional box construction with sharp edges is used, then box fabrication is achieved, but bag integrity is compromised due to internal edges or corners

Engineering Contradiction:

Improvebag damage from sharp edgesVSAvoidinternal edge elimination

Core Design Contradiction:

Object-affected harmful factorsVSShape

Solution Approach 1:

The box blank is designed with curved transition zones and rounded internal corners throughout its structure, eliminating sharp edges that could puncture or damage the bag while maintaining the overall cuboid external shape for efficient storage and shipping

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS12319478B2Box blanks, systems, and methods

Publication Date: 2025.06.03 GBS HOLDINGS LLC

AI summary

Box blanks, bag-in-box systems, and methods for forming bag-in-box systems from box blanks. The box blanks (100) include portions and flaps configured to fold and interlock with each other so as to improve structural integrity and reduce lateral deformation, have cross-corrugation and simplified fabrication, and have fewer or no internal edges or corners that may jeopardize the integrity of a bag of liquid or pourable powder contained therein.