Reusable Paperboard Container With Self-Locking Flap Assembly
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Solution Overview
Problem
Existing containers made from paperboard require expensive dedicated folding and gluing equipment for repeated use, and the folding sequence complicates the formation process.
Innovation Solution
A container design with specific angled flaps and locking tabs allows for manual erection and gluing without specialized equipment, enabling collapsibility and reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dedicated folding and gluing equipment is used for container assembly, then manufacturing precision and reliability are improved, but device complexity and cost increase
Solution Approach 1:
The container structure performs its own folding and locking functions through the interlocking flap and tab mechanism. The angled edges guide the folding process automatically, and the locking tabs engage with the flaps to secure the container without external equipment, enabling manual assembly while maintaining precision
Solution Approach 2:
The container is divided into modular components (panels, flaps, and tabs) that can be independently positioned and assembled. The blank is pre-scored with fold lines that segment the structure into manageable sections, allowing step-by-step manual erection without requiring complex integrated machinery
2Stability of the object's composition
If complex folding sequences are used for container formation, then structural integrity is improved, but ease of manufacture deteriorates
Solution Approach 1:
The blank is pre-configured with score lines, fold lines, and pre-positioned locking tabs during manufacturing. These preliminary features are created in advance so that during assembly, the user simply needs to fold along the pre-marked lines and the locking mechanism automatically engages, eliminating complex sequencing requirements
Solution Approach 2:
The locking mechanism uses asymmetric angled edges (first outer angled edge and second outer angled edge) that fit together in a specific orientation. This asymmetric design provides intuitive guidance for correct folding sequence and orientation, making the assembly process straightforward while ensuring proper structural alignment
3Productivity
If reusable container design is implemented, then productivity is improved, but ease of manufacture deteriorates due to additional structural features
Solution Approach 1:
The container is designed with dynamic characteristics that allow it to be easily collapsed and re-erected multiple times. The hinged connections at fold lines enable smooth transitions between collapsed and erected states, while the locking tabs provide stable locked positions during use, facilitating repeated reuse cycles
Solution Approach 2:
The locking and sealing functions are merged into a single integrated mechanism where the locking tabs and flaps work together. The same structural features that provide locking also create the sealed container shape, eliminating the need for separate locking components and simplifying manufacturing
Data Source
AI summary
A container is provided comprising: first and second side panels, a front panel, a back panel, first and second minor flaps, and first and second major flaps. The first minor flap may be coupled to the first side panel along a lateral edge of the first side panel, and the second minor flap may be coupled to the second side panel along a lateral edge of the second side panel. The first major flap may be coupled to the front panel along a lateral edge of the front panel, and the second major flap coupled to the back panel along a lateral edge of the back panel. The first major flap may comprise a first locking tab capable of engaging with the second major flap when the container is erected and the second major flap may comprise a second locking tab capable of engaging with the first major flap when the container is erected. The first and second minor flaps and the first and second major flaps may be folded inwardly along corresponding fold lines such that the first and second minor flaps are located inwardly from the first and second major flaps.