Recyclable Cardboard Product Packaging with Paper-Wrapped Finished Cavities

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Solution Overview

Problem

Existing product packages lack finished edges and cavities, resulting in an unfinished appearance and are not recyclable, which is unsuitable for luxury goods.

Innovation Solution

A package made from cardboard and paper, featuring finished edges and cavities, is manufactured by folding flat platform and tray elements to form a seamless assembly with a wrapper covering all edges, ensuring a finished, upscale appearance and recyclability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a package is made from cardboard material with open cavities, then it is recyclable and sustainable, but it lacks finished edges and has an unfinished appearance

Engineering Contradiction:

ImproverecyclabilityVSAvoidfinished appearance

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

A wrapper made from paper material is applied to cover the exterior surfaces of the cardboard platform and the interior side walls of the open cavity. This thin film approach provides finished edges and an upscale appearance while maintaining the recyclable cardboard structure underneath.

Inventive Principle:

Principle #30Flexible shells and thin films

2Ease of manufacture

If a package uses traditional construction methods, then it can be manufactured easily, but it exposes edges and lacks a seamless appearance

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidseamless appearance

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The wrapper acts as a flexible shell that conformally covers all exposed edges and surfaces of the cardboard structure, creating a seamless appearance while allowing the simple folded cardboard construction to remain intact.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The wrapper is nested within or around the cardboard structure, with the platform wrapper covering the exterior and the product tray wrapper covering the interior cavity walls, creating a layered finished appearance.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Adaptability or versatility

If a package is designed with cutout portions for products, then it conforms to product shape, but it creates exposed edges and an unfinished look

Engineering Contradiction:

Improveproduct conformityVSAvoidfinished edges

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

The wrapper provides different coverage qualities in different locations: the platform wrapper covers the exterior surfaces including cutout edges, while the product tray wrapper specifically covers the interior side walls of the cavity, ensuring all exposed edges are finished.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The flexible paper wrapper conformally adapts to the cutout portions and cavity shapes, providing finished edges that follow the product contours while maintaining the adaptive fit to the product shape.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentEP4288344B1Product package having finished edges and cavities

Publication Date: 2025.08.20 KNOLL PRINTING & PACKAGING

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AI summary

A package includes board platform having a folded top platform element and bottom platform element made from cardboard material. The top platform element has cutout portions conforming to shapes of a product to be packaged. A folded cardboard product tray element forms an open cavity conforming to the shape of the product and is secured to at least one of the top platform element and the bottom platform element and is disposed therebetween. A paper platform wrapper covers the exterior surfaces of the top platform element and a paper product tray wrapper covers the interior side wall of the open cavity.