Air Cushion Machine Void Volume Matching

Solution Overview

Problem

Existing air cushion machines often fail to accurately match the volume of air cushions to the void volume in a shipping box, leading to underfill or overfill, which can result in movement of items during shipment or difficulties in closing and stacking boxes.

Innovation Solution

An air cushion machine that determines the void volume between the box and the item and produces a specific quantity of air cushions with varying volumes to exactly match the void volume, using a controller to command the production of air cushions with a total volume equal to the void volume, allowing for inflation adjustment to achieve the correct total volume.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If air cushion volume is increased to fill void space, then cushioning coverage is improved, but box flap closure becomes difficult and stacking is compromised

Engineering Contradiction:

Improveair cushion volumeVSAvoidbox flap closure

Core Design Contradiction:

Quantity of substanceVSEase of operation

Solution Approach 1:

The air cushion machine dynamically adjusts the volume of air cushions based on real-time feedback from void volume measurement. The controller modulates the inflation process to produce air cushions with precisely controlled volumes that exactly fill the void space without overfilling, thereby maintaining ease of box flap closure while achieving complete cushioning coverage.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system incorporates a feedback mechanism where the void volume is measured (either by instrumentation or WMS calculation), this information is fed back to the air cushion machine controller, which then adjusts the air cushion production parameters to match the measured void volume exactly, preventing overfilling that would cause closure difficulties.

Inventive Principle:

Principle #23Feedback

2Ease of operation

If air cushion volume is decreased to facilitate box closure, then ease of operation is improved, but void volume coverage becomes insufficient causing item movement

Engineering Contradiction:

Improvebox flap closureVSAvoidair cushion volume

Core Design Contradiction:

Ease of operationVSQuantity of substance

Solution Approach 1:

The air cushion machine dynamically adjusts the volume of air cushions based on real-time feedback from void volume measurement. The controller modulates the inflation process to produce air cushions with precisely controlled volumes that exactly fill the void space without overfilling, thereby maintaining ease of box flap closure while achieving complete cushioning coverage.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system incorporates a feedback mechanism where the void volume is measured (either by instrumentation or WMS calculation), this information is fed back to the air cushion machine controller, which then adjusts the air cushion production parameters to match the measured void volume exactly, preventing underfilling that would cause item movement.

Inventive Principle:

Principle #23Feedback

3Productivity

If air cushion volume is precisely matched to void volume, then productivity is improved by eliminating adjustment time, but manufacturing precision requirements increase

Engineering Contradiction:

Improvecushion production efficiencyVSAvoidair cushion volume precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system uses feedback from void volume measurement to automatically adjust air cushion production parameters, eliminating the need for manual measurement and adjustment. This automated closed-loop control achieves precise volume matching while maintaining high productivity, as the system self-regulates without requiring operator intervention or complex manual calculations.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces manual measurement and adjustment mechanisms with automated instrumentation and electronic control systems. The void volume is measured by sensors or calculated by WMS, and the air cushion machine controller automatically adjusts production parameters based on this data, substituting mechanical adjustment processes with electronic control to achieve both precision and efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Ensures precise matching of air cushion volume to void volume, preventing item movement and box closure issues, while enabling efficient stacking and shipment by producing air cushions with customizable inflation levels to meet the exact void volume requirements.

Implementation Method 1

producing a quantity of air cushions with the air cushion machine having a total air cushion volume, the total air cushion volume being equal to the void volume

Methodology Applied

Scientific EffectAir injection and inflation:

Data Source

PatentUS10850906B2Air cushion machine and method

Publication Date: 2020.12.01 STOROPACK INC

AI summary

A method of producing air cushions with an air cushion machine for cushioning at least one item to be shipped in a box comprises the steps of determining a void volume defined by a difference between a volume of the box and a volume of the at least one item to be shipped in the box, and producing a quantity of air cushions with the air cushion machine having a total air cushion volume, the total air cushion volume being equal to the void volume.