Corrugated box box type and its size design

With the increase in the use of corrugated boxes by various industries in recent years, users have also put forward higher requirements for their functions. In terms of the structural design of the carton, especially in the case of container shipping and shelf storage, reasonable size, shape, and material allocation not only save costs, provide optimal packaging solutions, but also ensure that the product in the long-term shipping process Get the most effective protection. Under such circumstances, the structure and size design of corrugated boxes are also becoming increasingly important.

First, the corrugated box type standard

The size of the carton begins with determining the nature of the product and its type. Determine the box type before you can design and calculate the size of each part.

(I) International Carton Box Type Standard

There are two major categories of international corrugated box standards. One is the International Carton Box Standard, which was approved by the International Corrugated Board Association and jointly developed by the Federation of European Corrugated Cardboard Manufacturers (FEFCO) and the Swiss Board Association (ASSCO); One is the national standard of Japan and the United States. In the international carton box type standard, the textual name of the box type is indicated by a simple 4-bit to 8-digit number code, and various types of boxes are shown in the standard.

The uniform serial number indicates the different box type structure in the same box type, and the modification is the modification of the standard box type by each manufacturer. Different manufacturers of modified suffix code represent different types of boxes, but the same manufacturer should be the only one dedicated. Suffix codes facilitate the creation of a CAD/CAM library or a dedicated library gallery.

Such as commonly used type 02 carton, also known as slotted cartons, using a sheet of cardboard molding, Siamese upper and lower flaps can close the carton. The joints are generally joined at the carton factory by means of staples, adhesives or adhesive tapes. The length of the joints depends on the thickness of the corrugated board used, typically between 25 mm and 45 mm. Type 02 also has a bottom insert structure, which is characterized by preventing the contents from leaking from the bottom. Type 02 corrugated boxes are flat during transportation. When used, they are filled with sealing flaps and are most widely used.

(b) Domestic carton box type standard

China has developed the national standard GB/T6543-2008 “Single Corrugated Carton and Double Corrugated Carton for Transportation Packaging” with reference to international standards, and stipulates the basic types of single corrugated cartons and double corrugated cartons for transport packaging.

The code of the box type specified in this standard consists of four digits. The first two digits of the code indicate the box type, and the last two digits indicate the different carton patterns of the same type of box. At present, China's commonly used corrugated boxes are mainly 02 categories in the standard, namely A-type boxes in the US and Japan standards. In category 02, there are 0201 boxes (flat carton), 0202 carton (overlap carton), and 0203 carton (large carton). The above box-type structures are all designed according to the needs of the packaged goods, and the carton is generally flat. The structure of the spouted cartons has a protective effect on certain commodities, such as some volume-expanding cotton clothes, etc., which will compress after being pressed for a period of time. If they are packaged in flat carton boxes, the flaps on both sides of the cartons will inevitably fail to meet. The goods in the box are exposed. The use of a spouted cartons is more appropriate, and the number of spouts can be based on specific circumstances. The neatly-covered carton is neat in appearance and has better protection performance for the contents than the first two. However, the consumption of raw materials is also relatively large and the production process is somewhat complicated.

Model 03 is a nested type carton. It is a box composed of a few sheets of box blanks. Its feature is that the box is separated from the box lid (top lid, bottom lid). When used, the lid and box are sleeved. Type 04 is a folding carton, usually consisting of a piece of corrugated cardboard, folded into the bottom of the box, without nailing or bonding, production can also be manufactured according to the requirements of other types of ordering contract.

China's corrugated carton code is defined by the type of corrugated board, which is divided into 3 categories and divided into 5 categories, corresponding to the type of corrugated board. All kinds of corrugated box code, specifications and use occasions can be found in the national standard. Type 1 cartons are mainly used for the transportation and packaging of export and valuables, and do not use B or BB corrugated; Type 2 cartons are mainly used for the transport packaging of domestic products; 3 types are mainly used for the transportation and packaging of short-distance and low-value commodities.

In the design or selection of corrugated boxes, consideration should also be given to the selection of suitable corrugated board, including corrugated type, number of layers of cardboard, original paper specifications, etc., which are clearly defined in the relevant standards and materials.

Second, the size of corrugated carton design

Before determining the structural dimensions of a corrugated box, first consider the maximum outer diameter of the inner product, the nature and the tolerance coefficient of the product itself, and whether the inner product is a whole or a combination. At the same time, we must also consider various attachments added to protect the interior goods. This requires that the influence of various factors on the structural size of the corrugated box be considered in the design arrangement and the layout of the structure.

(I) Size regulations

The specifications of the carton are generally represented by the length, width and height of the inside diameter of the carton, and are given in the following order and code, in mm.

a. Length (L): the length of the long side of the bottom area in the box;

b. Width (B): short-side dimension of the bottom area in the box;

c. Height (H): Top to bottom dimensions in the box.

Corrugated carton size design includes inner diameter dimensions, manufacturing dimensions and outer diameter dimensions. The inner diameter size is the internal space size of the corrugated box after the box is formed; the outer diameter size is the outer contour size of the corrugated box after the box is formed, and can be expressed by the actually manufactured size plus the thickness of the corrugated cardboard used; the corrugated cardboard box is manufactured in the manufacturing process The dimensions can be made by using the inner diameter size plus the thickness of the corrugated board used.

(b) Design and calculation of dimensions

1. Calculation of inner and outer diameters and manufacturing dimensions

The factors determining the inner diameter size mainly include the maximum outer diameter size of the contents, the tolerance coefficient determined according to the contents, the arrangement of the contents, and the relevant dimensions of the inner liner and the buffer. The calculation of the inner diameter size can be obtained by the following formula:

Xi= Xmaxnx+d(nx-1)+k'+T.

In the formula, Xi is the carton inner diameter size; Xmax is the maximum outer diameter size of a single contents; d is the number of arranged contents in a certain direction in the carton; k' is the carton inner diameter size compensation amount; T is the total number of spacers or buffers thickness. The unit of length is mm. It is necessary to satisfy the outer diameter size of the Xi > built-in product. The correction factor and tolerance coefficient can be found in the table.

The calculation of the manufacturing size is:

X=Xi +t +k

In the formula, the size of the corrugated board is made, the thickness of the board is the correction factor. The size of the value is related to the specific size of the carton. In actual use, due to the rebound effect of the inner flap, it tends to tilt outwards. To reduce the increase in headroom due to this reason, the value in the height direction should be 2t
The outer diameter size is calculated as:

X0=X+K

In the formula, X0 is the outer diameter size, and K is the correction coefficient.

2. Calculation of carton flap size

The manufacturing size of the flap cover outside the corrugated box is also a key part to pay attention to. In the box type with the butt-sealed cover of the corrugated cardboard box outside, such as 0201, 0204, 0207, etc., the theoretical value of the manufacturing width of the swing cover width should be half of the manufacturing width of the box width. However, due to the rebound action of the inner flap, the lid is not horizontal but is slightly inclined, and the outer flap must produce a certain gap at the butt joint. Therefore, the width of the outer flap is not half the width, but slightly longer, so an amplification factor must be added to the actual production. The magnification factor can be calculated by a trigonometric function. However, due to the plasticity of the carton itself and for ease of calculation, most companies have calculated a fixed magnification factor based on the thickness of the cardboard. The following table shows:

Carton cover zoom factor

Cardboard thickness 3 mm or less 3 mm~5 mm 5 mm~8 mm 8 mm~12 mm

Magnification without enlargement 1 mm Increase 3 mm Increase 4 mm increase

Of course, such a magnification factor is only suitable for a general corrugated cardboard box. If a carton requiring a high degree of flapping is encountered, the magnification factor of the cardboard box flap can be obtained through a function. In addition, the magnification factors listed above are not suitable for carton widths below 20 cm.

3 joint size design

Corrugated cartons are formed by gluing and stapling joints. The dimensions of the joints are generally determined according to the number of corrugated layers and the level of processing at the factory. In order to keep the printed surface of the main surface (LH surface) from being damaged, the connector should generally be connected to the LH surface. Single corrugated joints are generally 35 mm to 40 mm in size, double corrugations are 45 mm to 50 mm, and three watts are 50 mm.

4. Calculation of carton blanking specifications

The cartons currently produced are mainly 0201 type corrugated cartons, as shown below. Based on the above, it is possible to calculate how much material is needed to put an ordinary 0201 carton into production.

0201 carton structure and development

Cardboard length = 2L + 2B + carton tongue;

Cardboard width = H + 2 times the carton flap.

According to the formula, we calculate the blanking specifications of the carton. Here, the carton's net specifications are calculated and trimmed during production. In order to save material as much as possible, the size of trimming is generally no more than 1 cm. There is no need to trim the edges near the tongue. Shaped box blanking size can be calculated based on the same principle, but different box type calculation formula is not the same.

Third, the size of the correction problem

In general, corrugated cardboard needs to be well bent through a molding process. Molding breaks down the structure of the corrugated board, which can cause shrinkage of the liner and extension of the tissue. This type of bending changes the corrugated board's extension to the basic dimensions of the corrugated box design. Therefore, the inner diameter of the corrugated box is slightly shorter than the distance between the line and the press line when the corrugated box is unfolded. This will add the reduced part of the size, which is closely related to the thickness of the corrugated board used. In the actual production of corrugated cartons, appropriate correction factors and additional dimensions are selected according to the specific equipment used. The correction factor value lookup table is available.

Making corrugated boxes is generally based on the inner diameter dimensions. Because the inner diameter size is relatively easy to determine, it is measured and determined in physical measurements or in outer diameters in a combination of packages and a reasonable arrangement. However, in actual operation, whether it is the calculation of the freight rate or the volume of the box face mark, the size of the outer diameter shall prevail. Therefore, in the corrugated box design, not only the manufacturing size is determined according to the inner diameter size, but also the outer diameter size is calculated based on the manufactured size.

Of course, the outer diameter size of the carton can also be determined according to the inner diameter size of the tray or the container, so that the length, width, height of the carton can be adapted to the transportation means, mechanized transportation can be realized, and the transportation efficiency can be improved. Due to the different stacking modes of corrugated boxes, the vertical projected area of ​​the stacked objects should be adapted to the size of the pallet. If the box size calculated from the inside to the outside of the carton can be basically matched with the box size calculated from the outside to the inside, the optimized corrugated box size can be obtained. Of course, the best design plan should still be carried out from the outside to the inside.

In actual production, customers often provide us with only the size or style of the product, which requires us to calculate the outer diameter size and manufacturing size of the carton. In particular, the use of containerized products is particularly important for calculating the outer diameter of a carton. In the corrugated box, although it is possible to directly measure the specific size of the corrugated box, in the measurement process, due to the influence of the indentation line, the result of the measurement may be inaccurate. In particular, the measurement of the size of used used carton should be strictly measured to ensure the accuracy of the size design, ensure the smooth completion of the late pallet or container loading, and can well protect the goods. A good carton design can save a lot of money on transportation.

IV. Methodological principles in design

The design of packaging structure is based on the actual conditions of packaging and production, and based on scientific principles, the design of the packaging's exterior structure and internal accessories is carried out. The design must ensure that the structure has sufficient strength, hardness and ability to resist other environments. From the perspective of packaging, we must consider the following two aspects: first, the primary function of protecting products, and second, meeting the important characteristics of modern packaging, such as transportation and processing characteristics.

Qualified cartons start with the right structural design. Designers must not only understand the customer's intentions, but also be familiar with the post-processing process. Only in this way, can the customer's intentions be converted into qualified products, and can ensure the smooth processing of the sequential processing. Designers must understand the nature, shape, size, weight of the contents, the arrangement of the contents, the transportation method, the stacking method, the storage environment, the transportation route and the time of the contents, the carton box type, and the production materials before the design begins. information.

The domestic carton design has some problems in terms of technology and guiding ideology, and lacks systematic analysis, so that the designed packaging cannot meet the requirements of ergonomics and technical and economical rationality. This point is very clearly reflected in the current carton size design.

At present, China only makes clear regulations for the box type of the carton, but there is no specific requirement for the size of the carton, which is mainly determined by the designer. Designers in the determination of carton size is mainly to consider two factors: First, to contain the contents; Second, there is enough strength. In fact, there are many other factors that govern the size and shape of the carton. Apart from the contents of the package, there are many other factors, such as ergonomic factors, the size of the trays, the size of the freight cars, the size of the container space, and the size of the containers. Size and so on. These factors are independent of each other, but also restrict each other's influence; it is necessary to consider both the packaging function and convenience. Therefore, only the systematic and comprehensive control of all the constraints during design can really determine the size of the carton.

In summary, the size design of the carton is an important task in the structural design of the corrugated carton. A qualified carton product must be protective and well-shaped. In particular, a carton that combines the functions of sales packaging and transport packaging, the reasonable size will be the key to the design of the carton. Because the change in size will directly affect the various performance changes in the carton. In short, in the structural design of corrugated boxes, it is determined based on the used manufacturing equipment, different production processes, different types of corrugated corrugated paper, and the types and properties of the interior products. Only by grasping the structure and size-related content of the design corrugated boxes, can we create corrugated cartons that protect the goods and beautify them.

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