Tray and Cover Carton Structure for Heavy-Load Packaging
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Solution Overview
Problem
Existing cartons used for packaging multiple articles are inefficient in material usage, waste generation, and do not adequately secure the contents, particularly when handling heavy loads.
Innovation Solution
A package design comprising a tray and a separate cover formed from foldable flaps, where the flaps are hingedly connected to the edges of a top panel, allowing for secure enclosure of articles with minimal material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional cartons are used for packaging multiple articles, then the contents can be contained and transported, but material usage is inefficient and waste is generated
Solution Approach 1:
The package is divided into separate functional components: a tray for supporting the articles and a cover for securing them. The cover itself is segmented into a top panel and multiple foldable flaps that can be independently positioned. This segmentation allows each component to be optimized for its specific function while using minimal material.
Solution Approach 2:
The cover incorporates foldable flaps that can dynamically adjust to different package configurations. The flaps can be folded to different extents depending on the size and shape of the articles being packaged, allowing the same package structure to securely contain various loads without requiring additional materials.
2Strength
If traditional cartons are used, then contents can be held, but strength for transporting heavy loads is insufficient
Solution Approach 1:
The load-bearing function is distributed across multiple structural elements: the tray base and the multiple foldable flaps of the cover. Each flap can be configured to provide support at different locations, creating a distributed load-bearing system that achieves high strength with minimal material.
Solution Approach 2:
The foldable flaps utilize the third dimension (vertical folding) to create structural strength. By folding the flaps upward and over the articles, the package gains load-bearing capacity in the vertical dimension without requiring additional horizontal material, effectively using spatial configuration to achieve mechanical strength.
3Loss of substance
If minimal material is used for the package, then waste is reduced, but the security of contents within the carton is compromised
Solution Approach 1:
The foldable flaps can be dynamically configured to provide secure enclosure. The flaps can be folded to different extents and positions depending on the specific packaging requirements, allowing the same minimal material structure to adaptively secure different types and sizes of contents with appropriate protection.
Solution Approach 2:
The package structure allows for parameter changes in the configuration of the foldable flaps. By adjusting the fold angles, positions, and orientations of the flaps, the security and protection level can be varied to match different packaging needs, achieving reliable content security with minimal material through optimal parameter configuration.
Data Source
AI summary
Aspects of the disclosure relate to a package (P; P′; P″), a tray (90) and a cover (190; 290; 390) for packaging one or more articles (B) and blank (10, 110; 210; 310) for forming the same. A combination of a tray blank (10) and a cover blank (110; 210; 310) is disclosed. The cover blank (110; 210; 310) comprises a pair of foldable flaps (118, 120; 214, 216; 314, 316) hingedly connected to respective ones of opposed ends or sides of a top panel (114; 212, 312A/312B) of the cover blank. Each of the foldable flaps (118, 120; 214, 216; 314, 316) extends to a free end. A free end of a first one of the foldable flaps (118, 120; 214, 216; 314, 316) is disposed at a first distance (Wc1, Wc2, Lcf) from a free end of a second one of pair of foldable flaps (118, 120; 214, 216; 314, 316) when in an erected form to create a cover (190; 290; 390). The first distance (Wc1, Wc2, Lcf) is equal to or less than a linear dimension (Lt1, Wt2) of a tray (90) formed from the tray blank (10).