Interlocking Flap Container Blank with Integrated Handle
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Solution Overview
Problem
Existing packaging solutions for containers, such as those used for food and beverages, require more material than typical containers, compromising cost-effectiveness and convenience in forming and using the containers.
Innovation Solution
A container blank comprising two primary panels, interlocking flaps, and a handle, where the panels are hingedly coupled to allow for easy formation into a box configuration, reducing material usage and manufacturing costs while providing a convenient handling mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If packaging solutions include handles, locking inserts, extended flaps, then container functionality is improved, but material usage and cost increase significantly
Solution Approach 1:
The patent combines multiple container features (handle, locking mechanism, flaps) into a single integrated blank structure. The handle is formed from the same blank material as the container body, and the locking flaps are integrated into the blank design, eliminating the need for separate components and reducing overall material usage while maintaining functionality.
Solution Approach 2:
The blank is designed to perform multiple functions simultaneously: it forms the container body, creates the handle structure, provides locking mechanisms through interlocking flaps, and enables rapid assembly. This multi-functionality reduces the need for additional specialized components that would increase material usage.
2Ease of operation
If packaging solutions include handles, locking inserts, extended flaps, then container functionality is improved, but manufacturing cost increases
Solution Approach 1:
By integrating all container features into a single blank, the patent reduces manufacturing steps, eliminates multiple assembly operations, and simplifies production. The handle, locking mechanisms, and container body are all formed from one piece of material through folding and interlocking, significantly reducing manufacturing complexity and cost.
Solution Approach 2:
The blank is designed to self-assemble into the finished container through simple folding and interlocking of flaps. The structure includes self-aligning features and automatic locking mechanisms that require minimal manual intervention or specialized equipment, reducing manufacturing labor costs and complexity.
3Quantity of substance
If typical container designs are used, then material usage is reduced, but container functionality and convenience deteriorate
Solution Approach 1:
The blank is divided into distinct functional zones including panel portions for the container body, flap portions for locking mechanisms, and handle portions. This segmentation allows each area to be optimized for its specific function while maintaining material efficiency through the integrated design.
Solution Approach 2:
The patent utilizes the two-dimensional blank layout to create three-dimensional container features. The handle is formed by folding and interlocking flap portions in different spatial dimensions, and the locking mechanisms are created through multi-layer flap arrangements, maximizing functionality within minimal material constraints.
4Ease of operation
If complex packaging solutions are used, then container functionality is improved, but box forming convenience and speed deteriorate
Solution Approach 1:
The blank features self-assembling characteristics with automatic alignment and locking mechanisms. The interlocking flaps naturally guide the assembly process, and the handle structure self-forms through simple folding actions, enabling rapid container formation without complex tools or multiple assembly steps.
Solution Approach 2:
The blank is pre-configured with pre-folded sections, pre-positioned flaps, and pre-aligned hinge lines that guide the assembly process. This preliminary preparation of the blank structure enables rapid container formation by eliminating the need for complex assembly operations during the box forming process.
Data Source
AI summary
A blank used for making a container is disclosed. The blank comprises a first primary panel, a second primary panel, and a secondary panel. The first primary panel is hingedly coupled to a first primary flap. The second primary panel is hingedly coupled to a second primary flap. The secondary panel is hingedly coupled to a secondary flap. The first primary flap comprises a main portion and a tip portion. The main portion is hingedly coupled to a first handle. The tip portion is positioned between the main portion and the first handle. The secondary flap is configured to be positioned between the second primary flap and the main portion when the container is in a box configuration. The tip portion is configured to be positioned between the second primary flap and an interior space of the container when the container is in the box configuration.