Paperboard Panel with Monolithic Spacer Structure
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Solution Overview
Problem
Conventional corrugated paperboard panels require significant material usage, leading to high costs, and there is a need for a material that offers strength, durability, and versatility while reducing material consumption.
Innovation Solution
A paperboard panel design featuring a first and second linerboard with a spacer structure comprising a flap member extending monolithically from one of the linerboards, where the tip of the flap is coupled to the inwardly-facing surface of the other linerboard, formed through die cuts and folding processes to create a stable and cost-effective configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional corrugated paperboard panels are used, then strength and durability are achieved, but material cost increases significantly
Solution Approach 1:
The invention divides the traditional three-layer corrugated structure into separate components: a first linerboard, a second linerboard, and discrete spacer structures positioned between them. This segmentation allows each component to be optimized independently and reduces overall material usage while maintaining structural integrity through the spaced configuration.
Solution Approach 2:
The invention extracts the corrugated medium layer from the traditional corrugated structure and replaces it with simplified spacer structures. These spacers are formed by cutting and folding flaps from the linerboards themselves, eliminating the need for a separate corrugated medium layer and reducing material cost while preserving the necessary spacing and structural support.
2Quantity of substance
If material usage is reduced, then material cost decreases, but strength and durability may be compromised
Solution Approach 1:
The invention transitions from a continuous three-layer structure to a spaced configuration where linerboards are separated by discrete spacer elements. This dimensional change creates void spaces between the linerboards while maintaining structural integrity through the strategically positioned spacers, reducing material usage while preserving durability.
Solution Approach 2:
The invention creates a composite structure combining linerboard materials with spacer elements formed from the same or different linerboard portions. This composite approach allows optimization of each component's function while achieving overall structural reliability with reduced total material usage.
Data Source
AI summary
A method for fabricating a sheet structure from paper and/or paperboard material, which provides a thickness dimension ordinarily associated with corrugated paperboard material. The sheet structure is constructed from a first planar linerboard sheet and a second non-planar linerboard sheet, wherein a plurality of projections are cut and folded from the second linerboard sheet and are adhesively coupled to the first linerboard sheet, such that portions of the projections define a standoff between the first and second linerboard sheets.