Partitioned Article Carrier Blank for Low-Waste Heavy-Load Containment
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Solution Overview
Problem
Existing article carriers require significant material usage and are not efficiently designed for minimal waste and secure article containment, especially when handling heavy loads.
Innovation Solution
A carrier design featuring a partition structure with weakened lines and foldable panels that minimize material usage while allowing easy assembly and secure article separation, using a sheet material like paperboard with tear-resistant coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional carrier designs are used, then article containment is achieved, but material usage is excessive and waste is high
Solution Approach 1:
The partition structure is divided into multiple panels (first partition panel, second partition panel, securing panel) that can be separately formed and assembled. This segmentation allows for optimized material usage in each panel while maintaining the overall containment function through the coordinated assembly of these discrete components.
Solution Approach 2:
The partition panels are hingedly connected to form nested structures where panels fold into one another. The first partition panel connects to the second partition panel, which in turn connects to the securing panel, creating a compact nested arrangement that minimizes material footprint while providing secure article separation.
2Ease of operation
If complex partition structures are used, then article separation is improved, but assembly complexity increases
Solution Approach 1:
The partition panels are pre-formed with integrated hinge connections and securing features during manufacturing. The blank is designed with pre-positioned fold lines and cut lines that establish the correct geometry before assembly, allowing the carrier to be quickly assembled by simple folding and securing actions rather than complex construction steps.
Solution Approach 2:
Multiple functions are merged into the partition structure: the first and second partition panels provide article separation, while the securing panel integrates both separation and securing functions. The hinge connections combine articulation with structural support, reducing the need for separate components and simplifying assembly.
3Loss of substance
If minimal material is used, then waste is reduced, but structural integrity for heavy loads is compromised
Solution Approach 1:
The partition structure utilizes thin, flexible partition panels that can bend and conform during assembly while maintaining sufficient strength for load-bearing. The hinged connections allow the panels to flex under heavy loads without breaking, providing structural integrity through flexibility rather than rigid thick material.
Solution Approach 2:
The carrier employs composite construction combining different panel types (partition panels, securing panel, end panels) with varying material properties. The blank is formed from material with optimized fiber orientation and density distribution, creating regions of higher strength where needed (at hinge connections and securing points) while using minimal material in less critical areas.
Data Source
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AI summary
Aspects of the disclosure relate to an article carrier (90) and to a blank (10; 110) for forming the same. The carton (90) comprises first and second panels (14/18, 28/24; 122/114, 124/118), disposed in opposition to each other. The carton (90) comprises a partition structure (P1, P2) extending between the first and second panels (14/18, 28/24; 122/114, 124/118). The partition structure (P1, P2) comprises a partition panel (66; 160) and a securing panel (68; 162). The partition panel is hingedly connected to the first panel (14, 28; 122) by a first fold line (69, 161). The securing panel (68; 162) is foldably connected to the partition panel (66; 160) by a joint portion (66B, JP) of the partition panel. In the blank form, the securing panel (68; 162) is defined at least in part by a cut line (71; 169) having a terminal end (Te) proximate to a free end (E1) of the partition panel (66; 160). The cut line (71; 169) defines a notional line (N1) passing through the terminal end (Te) and parallel to the first fold line. The joint portion (66B, JP) comprises a weakened line (79, 167) spaced apart from the notional line (N1).