Paperboard Packaging Container Curled Edge Design
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Solution Overview
Problem
Disposable paperboard packaging containers for products like infant formula and tobacco face challenges in minimizing carbon footprint and making containers recyclable, with existing solutions resulting in less attractive and less wear-resistant curled edges due to the rigid paperboard material structure.
Innovation Solution
A method of forming paperboard packaging containers using a rectangular body blank with parallel crease lines and bridging crease lines to create a curled edge, eliminating the need for plastic rims and enhancing recyclability by forming a stable, neat, and distinct curled edge through controlled fiber breakage and embossing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plastic rims are attached to improve appearance and wear resistance, then the container becomes less recyclable and has higher environmental impact
Solution Approach 1:
The invention extracts and eliminates the plastic rim component from the container structure. Instead of attaching plastic rims to the paperboard container, the patent uses the paperboard material itself to form the necessary structural features through crease lines and curling, thereby removing the harmful plastic component while maintaining functionality.
Solution Approach 2:
The invention changes the physical state and structural parameters of the paperboard material by introducing crease lines and curling mechanisms. These parameter changes enable the paperboard to achieve the structural integrity and wear resistance previously provided by plastic rims, allowing the container to maintain strength while being fully recyclable.
2Shape
If plastic rims are attached to improve appearance, then the container becomes less recyclable and has higher carbon footprint
Solution Approach 1:
The invention removes the plastic rim component that degrades appearance and increases carbon footprint. The paperboard container uses integrated crease lines and curling features to provide the necessary structural definition and aesthetic appeal without requiring additional plastic components.
Solution Approach 2:
The invention maintains material homogeneity by using only paperboard throughout the container structure. The crease lines and curling features are formed directly in the paperboard material, ensuring the entire container is made from the same recyclable material without heterogeneous plastic components.
3Shape
If the bottom is made from a folded-in end portion to improve appearance, then the structure becomes more complex and manufacturing becomes harder
Solution Approach 1:
The invention segments the container formation process into distinct stages: first forming the tubular body with crease lines, then separately curling the end portion. This segmentation allows each operation to be optimized independently and simplifies the manufacturing process compared to attempting to form the complete structure in a single complex operation.
Solution Approach 2:
The invention performs preliminary actions by pre-forming crease lines in the paperboard before curling the end portion to create the bottom. These pre-formed crease lines guide the subsequent curling operation and make the manufacturing process more straightforward by preparing the material in advance for the final shaping step.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces packaging containers with improved stackability, wear resistance, and recyclability by forming a curled edge that is both stable and aesthetically pleasing, reducing the need for plastic components and enhancing the container's overall performance during transport and storage.
Implementation Method 1
The crease line forming station may form the crease lines by pressing a crease line forming tool into the rectangular body blank such that two or more compressed crease lines are formed in the material.
Implementation Method 2
the crease lines formed by for example by applying pressure to the paperboard material breaks the fibers in the structure
Implementation Method 3
forming a curled second edge by curling the second end of the container body wall inwardly, at the two or more parallel crease lines and at the bridging crease line area
Implementation Method 4
sealing together the first and the second side edge, i.e. from the first end edge to the second end edge, in a but-to-but seal using a sealing strip
Data Source
AI summary
A method of forming a paperboard packaging container from a rectangular body blank is disclosed, the method including the following steps:a) providing a rectangular body blank made from a laminate sheet material;b) forming a tubular container body from the rectangular body blank, the container body having a first end with a first body opening and a second end with a second body opening;c) sealing together the first and the second side edge in a but-to-but seal using a sealing strip having a sealing strip width;d) presenting the tubular container body to a crease line forming station;e) closing the second body opening by pressing a paperboard disc into the second body opening;f) forming a curled second edge by folding or rolling the second end of the container body wall inwardly;g) filling the packaging container with bulk solids; andh) closing the first body opening.