Asphalt Sealer Packaging Reducing Weight and Dispensing Mess
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Solution Overview
Problem
Conventional 5-gallon plastic buckets used for driveway sealers and repair materials are heavy, difficult to handle and dispense, and create packaging density and waste issues during shipping and storage.
Innovation Solution
A polyhedral shaped packaging system comprising a corrugated cardboard outer housing and a high temperature stable gusseted bag with a handle and tongue projection for easy handling and controlled dispensing, allowing for efficient stacking and recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional 5-gallon plastic buckets are used for packaging driveway sealers and repair materials, then the product can be contained and transported, but the packaging becomes heavy and difficult to handle
Solution Approach 1:
The packaging system divides the containment function into two separate components: an outer cardboard housing and an inner flexible bladder. This segmentation allows the heavy liquid contents to be isolated in the bladder while the outer housing provides structural support and handling features, reducing the effective weight that users must maneuver.
Solution Approach 2:
The flexible bladder acts as an intermediary between the liquid contents and the outer housing. It provides a lightweight containment layer that can be easily manipulated within the rigid cardboard structure, allowing users to control dispensing without moving the entire heavy bucket.
2Quantity of substance
If conventional 5-gallon plastic buckets are used, then the product is contained securely, but the packaging creates density limitations during shipping and storage
Solution Approach 1:
The inner flexible bladder is nested within the outer cardboard housing, creating a compact nested structure. When empty, the bladder can be collapsed and stored within the housing, significantly reducing the volume occupied during storage and shipping while maintaining the same capacity for liquid contents when filled.
3Ease of operation
If conventional 5-gallon plastic buckets are used, then the product can be dispensed, but the dispensing process becomes difficult and messy
Solution Approach 1:
The packaging system transitions from a static rigid bucket to a dynamic flexible bladder within a rigid housing. The bladder can be squeezed, compressed, and manipulated to control liquid flow dynamically, allowing users to dispense precise amounts without spilling or creating messes.
Solution Approach 2:
The flexible bladder made of thin film material allows for precise control of liquid dispensing through manual compression and manipulation. Users can squeeze the bladder to release controlled amounts of liquid directly where needed, eliminating the mess associated with pouring from rigid containers.
4Strength
If conventional plastic buckets are used, then the packaging provides structural integrity, but it creates expensive and non-recyclable waste
Solution Approach 1:
The packaging system uses composite materials: a cardboard outer housing for structural strength and recyclability, combined with a flexible plastic bladder for liquid containment. This composite approach allows each material to perform its optimal function while improving overall recyclability compared to traditional plastic buckets.
Solution Approach 2:
The liquid containment function is extracted into a separate removable bladder, allowing the outer cardboard housing to be reused or recycled independently. The bladder can be removed and disposed of separately, reducing the amount of non-recyclable material in the overall packaging system.
Data Source
AI summary
The asphalt sealer packaging and dispensing system includes a pre-portioned, modular containment for a volume of cold pour asphalt sealer. The modular containment forms a cube shaped outer corrugated cardboard housing having a high temperature stable bladder insert. The bladder insert forms an upper handle that may extend through a first slot for handling and control of the outer housing. A dispensing tab may be formed as a tongue extension that extends through an opposing second slot. Shearing the outer terminus of the tongue extension thereby forms a shaped spout for allowing a linear output of asphalt sealer to be directly dispensed into a target surface.