Folded Paperboard Carrier Pockets for Product Alignment
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Solution Overview
Problem
Existing packaging solutions face challenges in maintaining product alignment during shipping and display, particularly in multi-pack arrangements, and there is a growing need for environmentally friendly alternatives to plastic materials like molded plastic inserts and blister packs.
Innovation Solution
A carrier made of cardboard or paperboard with foldable sheets, featuring pockets defined by hinged flaps and tabs, allowing products to be positioned correctly before packaging and facilitating high-speed assembly without plastic use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If molded plastic inserts are used to locate products within a package, then product alignment and positioning are achieved, but environmental sustainability deteriorates due to plastic waste and recyclability issues
Solution Approach 1:
The patent changes the material parameter from plastic to cardboard/paperboard, transforming the locating means into a recyclable, environmentally friendly material while maintaining the structural functionality for product positioning and alignment within the package
Solution Approach 2:
The patent employs disposable cardboard locating means that can be easily manufactured and discarded after use, replacing durable plastic inserts with a single-use, biodegradable alternative that reduces environmental persistence of packaging waste
2Object-affected harmful factors
If cardboard locating means integral with the outer package are used, then environmental sustainability is improved, but manufacturing complexity increases and high-speed machine erection is not suitable
Solution Approach 1:
The patent divides the packaging system into separate components: the outer package and the locating means (tray) are manufactured independently and then assembled together, simplifying the manufacturing process for high-speed production while maintaining environmental sustainability
Solution Approach 2:
The locating means is pre-formed as a separate tray component with integrated product positioning features before assembly into the final package, allowing for standardized, efficient manufacturing and high-speed assembly operations
3Productivity
If products are loaded into locating means already within the outer package, then assembly efficiency is improved, but adaptability deteriorates as the locating means cannot be adjusted for different product sizes
Solution Approach 1:
The patent incorporates flexible or adjustable elements in the locating means, such as movable walls or adaptable positioning features, allowing the tray structure to be adjusted for different product sizes and configurations while maintaining efficient assembly processes
Data Source
AI summary
A carrier (2) made of cardboard, paperboard or other lightweight foldable sheet material, comprises a top sheet (4) defining one or more pockets (20) for receiving one or more products and a bottom sheet (6) attached to the top sheet (4). The top sheet (4) comprises one or more respective sets (30) of flaps (32) for forming the respective pockets (20), each flap (32) being hingedly connected at a proximal end (36) to a top surface (38) of the top sheet (4) about a respective flap hinge line (40) defined around an upper edge (42) of the respective pocket (20) and folded about the respective flap hinge line (40) to define a pocket side wall. The top sheet (4) further comprises respective tabs (50) hingedly connected to distal ends (46) of the respective flaps (32) about respective tab fold lines (52) and folded about a respective tab fold line (52) so as to lie along a base of the pocket (20). The bottom sheet (6) is bonded to the respective tabs (50) in a face to face relationship to close at least a portion the base of the pocket (20).