Polygonal Container With Interlocking Bottom Panels
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Solution Overview
Problem
Existing rectangular containers are not suitable for packaging non-rectangular items, lacking space efficiency and strength for stacking or bulge resistance, making non-rectangular containers with interlocking bottom panels desirable for packaging applications.
Innovation Solution
A polygonal container is constructed from a blank of sheet material with interlocking bottom panels, featuring locking slots and tabs that secure the bottom panels together without adhesives, allowing for efficient space use and enhanced stacking strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If rectangular containers are used, then manufacturing is simple, but space efficiency and stacking strength are insufficient for non-rectangular items
Solution Approach 1:
The bottom wall is divided into multiple separate bottom panels that are inserted into corresponding recesses in the side and end walls. This segmentation allows the container to achieve both non-rectangular shapes for better space efficiency and structured interlocking for enhanced stacking strength.
Solution Approach 2:
The bottom panels are nested within recesses formed by the side and end walls, creating an interlocking structure. This nesting arrangement provides both the flexibility for non-rectangular configurations and the mechanical strength needed for stacking and bulge resistance.
2Ease of manufacture
If interlocking bottom panels are used without adhesives, then manufacturing simplicity is maintained, but structural strength may be compromised
Solution Approach 1:
The bottom wall is segmented into multiple panels that interlock with the walls through recesses and locking mechanisms. This segmentation enables adhesive-free assembly while maintaining structural integrity through the distributed interlocking design.
Solution Approach 2:
The bottom panels and wall recesses are designed with asymmetric geometries including locking tabs and slots that provide directional insertion and secure engagement. This asymmetric design ensures strong mechanical interlocking without requiring adhesives.
3Adaptability or versatility
If non-rectangular configuration is used, then space efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The container is divided into modular panels and walls that can be independently formed and then assembled. This modularity simplifies the manufacturing of complex non-rectangular shapes by breaking them down into manageable segments that interlock together.
Solution Approach 2:
The nested interlocking design allows complex non-rectangular configurations to be achieved through standardized joining mechanisms. The bottom panels nest into wall recesses using consistent locking tab and slot geometries, reducing manufacturing complexity despite shape variations.
Data Source
AI summary
A blank of sheet material for forming a polygonal container is provided. The blank includes two end panels, two side panels, and four corner panels connected in series along a plurality of fold lines. The blank further includes a plurality of bottom panels each extending from one panel of the end panels and the side panels. The plurality of bottom panels is configured to define a locking slot and a locking tab that is insertable into the locking slot to form a bottom wall of the container.