Polymer Truss Core in Cardboard Packaging
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Solution Overview
Problem
Corrugated cardboard boxes are prone to damage from compressive pressures and mishandling due to their weak structural frame, leading to potential damage of contents during transportation, and existing solutions like additional layering or load-bearing walls increase production and shipping costs.
Innovation Solution
Integration of a resilient polymer frame structure within the core of the cardboard box, using truss structures made of polymers like polypropylene or polystyrene, which enhances tensile and compressive strength without the need for extra material, thereby reducing tare weight and material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional layering or load-bearing walls are added to increase compressive strength, then the strength of the package is improved, but the tare weight and material costs increase
Solution Approach 1:
The patent changes the material parameter from paper-based flutes to polymer-based truss structures, fundamentally altering the structural properties. This enables achieving higher compressive strength with reduced material quantity and weight, directly resolving the contradiction between strength improvement and weight increase
Solution Approach 2:
The patent creates a composite structure combining polymer truss members with cardboard linerboards. The polymer trusses provide high-strength load-bearing capability while the cardboard provides surface integrity and bonding, achieving superior compressive strength without the weight penalty of traditional multi-layer cardboard constructions
2Strength
If additional layering or load-bearing walls are added to increase compressive strength, then the strength of the package is improved, but the production cost increases
Solution Approach 1:
The patent changes the structural configuration parameter from multiple cardboard layers to a single-layer cardboard with integrated polymer trusses. This simplifies the manufacturing process by reducing the number of layers to be assembled while maintaining or improving compressive strength, thereby reducing production costs
Solution Approach 2:
The patent extracts the load-bearing function from the cardboard flutes and transfers it to the polymer truss structure. This allows the cardboard to be used in a simpler, single-layer configuration focused on providing surface integrity, reducing manufacturing complexity and cost
3Strength
If the density of flutes is increased via layering to improve tensile and compressive strength, then the strength of the box is improved, but the tare weight increases
Solution Approach 1:
The patent uses composite materials where polymer truss members are integrated within the cardboard structure. The polymer material provides high tensile strength with low density, enabling tensile strength improvement without increasing tare weight, unlike traditional cardboard layering approaches
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 polymer frame structure significantly increases the crush strength of the package, providing better protection against compressive pressures and mishandling while maintaining a lower tare weight and material costs compared to traditional corrugated cardboard boxes.
Implementation Method 1
integrating a resilient polymer frame structure into the core frame of the box
Implementation Method 2
a truss structure that includes a core frame that suitably increases the tensile and compressive strength
Data Source
AI summary
A new package or box type having an internal core or frame structure comprising of plastic or other polymer material sandwiched between two cardboard sheets an all sides of the box forming the outer walls of the box. The walls of the box containing the frame structure are more resistant to bursting or crushing than conventional corrugated cardboard used in the industry for transporting goods. Use of plastic or polymers applied to the core frame results in less material consumption than conventional corrugated cardboard. This invention yields higher package strength throughout the package structure and not just the edge of the package in order to negate the use of the double corrugated walls design as widely used in corrugated card board to achieve similar package strength quality while minimizing package weight and preserving exterior package composition of cardboard for handling purposes.