Stackable Container Index Tab Curvature Design
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Solution Overview
Problem
Existing stackable containers with index tabs or projections often experience bending or weakening due to edge-to-edge contact during folding, leading to loss of function and reduced production yield.
Innovation Solution
A stackable container blank design featuring index fold-down flaps with notched or expanding extensions, where the angles and widths of the flaps and extensions are strategically configured to minimize contact and prevent unintended bending, along with a method of folding and gluing to secure these features in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If index tabs are formed by cutting material at 90° angle to fold line, then index tabs can be created for stacking, but the edge-to-edge contact causes bending or folding at wrong location
Solution Approach 1:
The patent applies curvature by replacing the straight edge with an arc-shaped edge on the index tab extension. This curved geometry prevents the extension from making full contact with the inner side wall during folding, eliminating the bending problem while maintaining the stacking function.
2Strength
If extensions are made straight to secure index tab, then full contact with inner wall occurs, but this causes extension to bend and weaken the index tab
Solution Approach 1:
The extension features an arc-shaped edge instead of a straight edge. This curvature creates a gap between the extension and the inner side wall during folding, preventing the bending that would compromise strength while still allowing the extension to perform its securing function.
3Ease of operation
If extensions have straight edge for full contact, then securing function is achieved, but bending occurs reducing production yield
Solution Approach 1:
The arc-shaped edge on the extension maintains the securing function by still allowing contact with the inner wall at critical points while the curved geometry prevents full-edge contact that causes bending. This eliminates defects and improves production yield.
Data Source
AI summary
A container blank, a stackable container, and a method for making a stackable container are disclosed. The container blank includes a base having first and second pairs of opposed base edges, end walls foldably attached to the first base edges, and side walls foldably attached to the second base edges. Each side wall has an outer wall foldably attached to the second base edge along a first fold line, at least one index fold-down flap attached to the outer wall along a second fold line, and an inner wall or inner wall flaps foldably attached to the outer wall along a third fold line. Each index flap has a distal portion with notched or expanding extensions, and optionally, a border at a first angle of less than 90° from the second fold line. The stackable container is made from the container blank (e.g., by the method).