Bicycle Packaging Inserts for Secure Transport

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Solution Overview

Problem

Conventional bicycle packaging methods, such as partial overlap boxes, often fail to securely hold bicycles during transportation, leading to potential damage and loss, as they lack effective mechanisms to stabilize and secure the bike within the packaging.

Innovation Solution

The proposed solution involves a method of attaching two packaging bodies to define a void for the bicycle, using primary and secondary fasteners to secure the top panels, and incorporating wheel and derailer inserts to stabilize the bike, along with a wedge insert to limit movement, all formed from materials like corrugated cardboard or other suitable materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional partial overlap box packaging is used, then the packaging structure is simple, but the bicycle cannot be securely held during transportation

Engineering Contradiction:

Improvesecurity of bicycle during transportVSAvoidpackaging structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The packaging is divided into multiple functional components: packaging body, wheel inserts, derailleur inserts, and wedge inserts. Each component serves a specific stabilization function, allowing the system to securely hold the bicycle without requiring a monolithic complex structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inserts made of corrugated cardboard or foam act as intermediary elements between the bicycle parts and the packaging body. These inserts fill voids and prevent movement, providing security without directly modifying the packaging body structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If adhesive is used to secure top flaps in conventional packaging, then the packaging can be sealed, but assembly and disassembly becomes difficult

Engineering Contradiction:

Improveease of assembly and disassemblyVSAvoidsecurity of packaging closure

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces adhesive bonding with a mechanical interlocking system using tabs and slots. This allows the packaging to be securely sealed while enabling easy assembly and disassembly through simple mechanical engagement and disengagement of the tab-slot connections.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If stabilizing inserts are added to secure the bicycle, then the bicycle stability improves, but the packaging complexity increases

Engineering Contradiction:

Improvestability of bicycle in packagingVSAvoidnumber of insert components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple stabilizing functions are merged into a single integrated insert structure. The wheel inserts, derailleur inserts, and wedge inserts work together as a coordinated system to stabilize the bicycle, reducing the need for numerous separate components while maintaining high stability.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20230278779A1Bicycle packaging and inserts therefor

Publication Date: 2023.09.07 PRATT CORRUGATED HOLDINGS INC

AI summary

A wheel insert for bicycle packaging includes a first insert panel configured to abut a side packaging panel of the bicycle packaging; and a second insert panel laterally offset from the first insert panel and configured to be spaced from the side packaging panel, the first insert panel defining an insert opening therethrough for receiving a wheel axle of a bicycle that is within the bicycle packaging.