Stackable Container Flute Coverage and Moisture Reduction
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Solution Overview
Problem
Conventional stackable containers made from corrugated board suffer from moisture collection in the flutes of the load-bearing walls, which weakens the structure over time due to outdoor precipitation and condensation, compromising their stackability and load strength.
Innovation Solution
The design incorporates a stackable container blank with foldable sidewall structures that include a wall flap, index fold-down flaps, and inner fold-down flaps, where the index and inner flaps alternate, forming projections that cover the flutes and provide indexing slots, while also allowing for air flow through triangularly shaped holes, enhancing the structural integrity and reducing moisture collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional corrugated board containers are used with flutes directed upward in load bearing walls, then the containers provide basic structural support, but moisture collects in the flutes due to precipitation and condensation, weakening the container over time
Solution Approach 1:
The patent inverts the conventional flute orientation by directing flutes horizontally rather than upward in load bearing walls. This inversion prevents moisture collection while maintaining structural integrity through alternative wall construction methods using folded flaps that create covered surfaces.
Solution Approach 2:
The patent introduces a new dimensional approach by adding folded wall flaps that extend beyond the flute surfaces, creating an additional protective dimension that covers the flutes and prevents moisture access while maintaining load bearing capacity.
2Ease of operation
If wall flaps are folded over each other to form projections for stacking, then stackability and indexing are achieved, but the flutes remain uncovered and susceptible to moisture collection
Solution Approach 1:
The patent segments the wall structure into multiple functional components: base flaps for stacking projections, intermediate flaps for coverage, and top flaps for additional protection. This segmentation allows each component to perform its specific function while collectively solving both stackability and moisture protection requirements.
Solution Approach 2:
The patent implements a nested flap structure where multiple layers of flaps are folded over each other in sequence, with each flap nested within the previous one. This nested arrangement creates multiple protective layers that cover the flutes while maintaining the indexing projections for stacking.
3Reliability
If additional flaps are added to cover flutes and provide indexing, then moisture protection and stackability are improved, but the container blank becomes more complex
Solution Approach 1:
The patent designs flaps that serve multiple functions simultaneously: the same folded flap structure provides both moisture protection by covering flutes and stackability through indexing projections. This multi-functionality reduces the need for separate components and simplifies the overall blank design despite the added protective features.
Data Source
AI summary
A stackable container and blanks for forming a stackable container are disclosed. In one embodiment, a stackable container has (a) a base having two pairs of opposed base edges, (b) two first sidewall structures foldably attached to the first base edges at an angle of from about 90 degrees to about 100 degrees, and (c) two second sidewall structures. The second sidewall structures generally each include (i) a wall flap foldably attached to one of the base edges at an angle of from about 90 degrees to about 100 degrees, (ii) an index fold-down flap foldably attached to the wall flap at an angle of about 180 degrees, and (iii) a plurality of inner fold-down flaps foldably attached to the wall flap at an angle of about 180 degrees. Embodiments of the present invention can advantageously provide a reliable design approach for making a stackable container from a blank, whereby the weight-bearing ability and/or stackability of the container is improved, while also covering flutes on the load-bearing wall, thereby reducing moisture collection.