Adhesive-Free Tray Packaging With Locking Flaps and Covers
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Solution Overview
Problem
Existing packaging solutions require adhesive, tape, or complex assembly maneuvers, leading to inefficiency and significant scrap material waste, while lacking a seamless, inviolable seal without additional components.
Innovation Solution
A folding plate system with integrated flaps and covers, utilizing a folding station with skids and optional upper supports, allows for quick assembly without adhesives or tape, and features a secure, tamper-evident seal using locking skids and vandal-proof perforations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive, tape, or complex assembly maneuvers are used for closing packaging, then the packaging can be sealed and secured, but the assembly process becomes inefficient and time-consuming
Solution Approach 1:
The packaging system uses self-closing flaps with integrated locking tabs that automatically engage with corner notches when the flaps are folded, eliminating the need for external adhesives, tapes, or complex assembly maneuvers. The structure serves itself by using its own geometric features to achieve secure closure.
Solution Approach 2:
The invention replaces chemical bonding (adhesive) and mechanical fastening (tape) with a geometric interlocking mechanism where locking tabs fit into corner notches through simple flap folding, significantly simplifying the assembly process while maintaining sealing integrity.
2Reliability
If traditional packaging designs are used, then closure can be achieved, but significant scrap material waste is generated due to inefficient surface utilization
Solution Approach 1:
The packaging plate is divided into functional zones: a central tray area, four corner notches, and four flaps with locking tabs. This segmentation allows each element to serve its specific purpose while optimizing the overall layout to minimize waste material.
Solution Approach 2:
The invention utilizes the third dimension by folding flat flaps upward and securing them with tabs that engage vertically with corner notches, transforming a two-dimensional surface utilization problem into a three-dimensional structural solution that maximizes material efficiency.
3Reliability
If adhesive or tape is used for sealing packaging, then the packaging can be closed securely, but additional components and complexity are introduced
Solution Approach 1:
The invention merges the sealing function into the structural elements of the packaging itself. The flaps, locking tabs, and corner notches are all integral parts of the single plate, eliminating the need for separate adhesive, tape, or additional fastening components.
Solution Approach 2:
The flaps serve multiple functions: they provide the sealing surface, contain the locking tabs for securing, and utilize the corner notches for positioning and engagement. This multi-functionality reduces the overall component count while maintaining reliable closure.
4Ease of manufacture
If self-assembly boxes with complex locking maneuvers are used, then the packaging can be secured without adhesive, but the assembly process remains time-consuming and inefficient
Solution Approach 1:
The packaging structure automatically secures itself through the geometric interlocking of tabs and notches when flaps are folded into place, requiring no complex manual locking maneuvers or specialized assembly tools, thus maintaining adhesive-free assembly while dramatically improving speed.
Data Source
AI summary
The present invention relates to a packaging system, which creates a packaging consisting of a rectangular or square tray, watertight perimeter flaps and two covers. It comprises a folding station consisting ofa frame with a central gap corresponding to the dimensions of the tray;a skid at each corner of the frame, protruding from the top.In turn, the plate comprisesa flap on each edge of the tray, joined together by corners comprising diagonal, radial notches,two covers on two flaps facing each other, each with a pair of insertion tabs for inserting between the flaps.