Reusable Break Pack Carton with Self-Locking Bottom Flaps
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Solution Overview
Problem
Conventional break pack cartons have limited reusability and are prone to small products falling out due to unsecured openings, leading to unacceptably low life cycles.
Innovation Solution
A reusable break pack carton design utilizing a single sheet of cardboard with self-locking flap portions that form a reinforced bottom wall, allowing for repeated assembly and disassembly without external securing means, preventing small objects from falling out by interlocking and forming a stable bottom structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional break pack cartons are used with simple construction, then ease of manufacture is improved, but reusability and life cycle deteriorate
Solution Approach 1:
The bottom wall is segmented into multiple flap portions (first, second, third flap portions) that can be independently folded and interlocked. This segmentation allows the bottom wall to be self-assembled and self-reinforced, improving structural integrity and reusability without complicating the manufacturing process.
Solution Approach 2:
The flap portions are designed to nest within each other during assembly, with the second flap portion containing the first and third flap portions. This nesting arrangement creates a compact collapsed state while enabling automatic interlocking that strengthens the bottom wall, enhancing both ease of manufacture and durability.
2Ease of operation
If conventional break pack cartons have open openings for access, then ease of operation is improved, but reliability deteriorates due to small products falling out
Solution Approach 1:
The bottom wall incorporates movable flap portions that can dynamically adjust during assembly. The interlocking flaps create a self-locking mechanism that passively prevents small products from falling out while maintaining easy access through the open top, resolving the contradiction between ease of operation and reliability.
3Reliability
If self-locking mechanisms are added to prevent products from falling out, then reliability is improved, but device complexity increases
Solution Approach 1:
The bottom wall flaps are designed to self-lock automatically during the assembly process without requiring external fastening mechanisms. The interlocking flaps create their own securing mechanism through the assembly motion itself, improving reliability while avoiding additional complexity from external fasteners, adhesives, or mechanical locks.
4Strength
If reinforced bottom wall structure is implemented, then strength is improved, but manufacturing precision requirements worsen
Solution Approach 1:
The bottom wall is divided into multiple flap portions that distribute structural loads across multiple elements rather than requiring a single complex reinforced structure. This segmentation achieves enhanced strength through the collective interlocking of simpler flap components, reducing the precision requirements for manufacturing each individual flap.
Data Source
AI summary
Exemplary embodiments of the present disclosure are directed to a reusable break pack carton formed using single sheet construction that has the ability to be repeatedly flattened and assembled without severing the joints. The break pack carton can include self-locking members configured to form a bottom wall of the break pack carton in the assembled state and a reinforced multi-layer top wall.