Packaging System for Brittle Ceramic Sheets Using Recessed Stack Holders
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Solution Overview
Problem
Brittle thin-sheet materials, such as ceramic sheets, are prone to breakage during transportation due to vibrations or drops, as existing packaging methods do not adequately protect them from direct contact with packaging containers or bags.
Innovation Solution
A packaging system featuring stacks of ceramic compacts as electrolyte sheets in a packaging container with recessed portions and stack holders made of antistatic material, where the stacks are positioned to face the bottom of the recessed portions, reducing the risk of breakage by distributing impact forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If brittle thin-sheet materials are packaged in portion bags and arranged upright in packaging boxes, then the packaging structure is simple and easy to assemble, but the materials are prone to breakage due to direct contact with the packaging box during transportation
Solution Approach 1:
The patent introduces stack holders as intermediary components between the brittle thin-sheet materials and the packaging box. These stack holders are specifically designed with recessed portions that cradle the stacks, preventing direct contact with the packaging box walls during transportation. This intermediary structure effectively distributes impact forces and eliminates the direct harmful contact that causes breakage in conventional packaging methods.
Solution Approach 2:
The stack holders are designed with buffer members integrated into their structure, providing beforehand cushioning for the brittle materials. The recessed portions of the stack holders create a protective cavity that absorbs and distributes impact forces before they can reach the thin-sheet materials. This prior cushioning mechanism ensures that even during rough handling or drops, the materials are protected from direct impact.
2Reliability
If buffer members are disposed on both sides of arranged packs, then some protection is provided, but the upper parts of the materials remain exposed and vulnerable to collision with the packaging box
Solution Approach 1:
The stack holders are designed as bag-like structures that envelop the entire stack of brittle materials, providing comprehensive protection similar to flexible shells. This bag structure extends protection to the upper exposed parts of the materials, completely enclosing them within the protective holder rather than leaving them exposed as in conventional packaging with side buffers only.
3Reliability
If stacks are fitted in recessed portions with faces oriented toward the bottom, then impact forces are distributed and breakage is reduced, but the packaging container design becomes more complex
Solution Approach 1:
The packaging system is segmented into distinct functional components: the packaging container body, multiple stack holders with recessed portions, and the stacks themselves. Each component has a specific function - the container provides overall structure, the stack holders provide individualized protection and proper orientation, and the stacks contain the materials. This segmentation allows the complex protection mechanism to be achieved through modular, standardized components that can be easily manufactured and assembled.
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A package (1) of the present invention includes: stacks (5) each including a plurality of brittle thin-sheet materials (50); stack holders (6) holding the stacks (5); and a packaging container including at least a body portion (4) having a plurality of recessed portions (41). The stacks (5), together with the stack holders (6), are fitted in the recessed portions (41) in such a manner that a face of each stack (5) that is formed along a stacking direction of the stack (5) faces a bottom face of the recessed portion (41). With this configuration, breakage of the brittle thin-sheet materials (50) can be reduced.