Adjustable Packaging Insert for Variable-Size Electronics
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Solution Overview
Problem
Existing packaging solutions for handheld electronic devices are inflexible and require multiple inserts for devices of varying sizes, leading to inefficiencies in storage and shipping, as they do not accommodate devices of different lengths, widths, and thicknesses effectively.
Innovation Solution
A modular packaging insert with adjustable end and side flaps that can be folded to accommodate electronic devices of various sizes by utilizing bend-enhancing portions and frangible sections, allowing for customizable void sizes within a single insert.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple pre-sized packaging inserts are used to accommodate electronic devices of varying sizes, then all device sizes can be fitted, but storage and shipping efficiency deteriorate due to the need for multiple insert types
Solution Approach 1:
The packaging insert is designed with multiple end flaps and side flaps that can be configured in different positions to create void spaces of various sizes. This single insert structure can accommodate electronic devices ranging from small smartphones to larger tablets, eliminating the need for multiple specialized insert types while maintaining storage and shipping efficiency.
Solution Approach 2:
The insert features movable end flaps and side flaps that can be selectively positioned along the longitudinal and lateral directions. This dynamic configuration allows the void space to be adjusted according to the size of the device being packaged, enabling one insert to serve multiple device size categories.
2Productivity
If a single packaging insert is used for all device sizes, then storage and shipping efficiency improves, but the ability to accommodate various device sizes deteriorates
Solution Approach 1:
The insert is divided into multiple functional components including end flaps, side flaps, and a bottom panel. These segmented elements can be independently positioned and configured to create customized void spaces, allowing the single insert to adapt to different device dimensions while maintaining structural integrity.
Solution Approach 2:
The flaps are designed to nest within each other when positioned in different configurations. The end flaps can be nested at different locations along the longitudinal axis, and side flaps can be nested at different locations along the lateral axis, creating a compact structure that adapts to various device sizes.
3Ease of manufacture
If fixed-size packaging inserts are used, then manufacturing simplicity is maintained, but flexibility to accommodate different device dimensions is lost
Solution Approach 1:
The insert is pre-manufactured with all the necessary flaps and structural elements in their potential positions. The bend-enhancing portions and frangible sections are pre-formed during manufacturing, allowing the insert to be easily configured into different shapes at the point of use without requiring complex manufacturing processes.
Solution Approach 2:
The insert design incorporates frangible sections that allow certain portions to be broken or separated to create different configurations. This parameter change from intact to broken states enables the same insert structure to accommodate different device sizes while maintaining manufacturing simplicity.
Data Source
AI summary
A packing insert includes a panel that defines a periphery, a location inward of the periphery, and a plurality of flaps each defining an outer end and an inner end such that each flap extends inwardly from its outer end to its inner end. Each of the flaps is foldable about its outer end so that the flaps collectively define a void. A first one of the flaps has a second outer end spaced outwardly from the outer end of the first flap. The panel defines at least one frangible portion between the outer end and the second outer end of the first flap. The first flap is selectively foldable about 1) its outer end so as to at least partially define the void, and 2) its second outer end, after breaking the at least one frangible portion, so as to increase a size of the void.