Cardboard Driveway Sealer Packaging with Spout Dispensing
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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 distribution and use.
Innovation Solution
A packaging system comprising a cube-shaped corrugated cardboard housing with a high-temperature stable, gusseted bag insert and blow-molded support insert, featuring filling and dispensing spouts for easier handling and application, and 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, then the product can be contained and transported, but the packaging becomes heavy and difficult to handle
Solution Approach 1:
The patent changes the packaging material from heavy plastic to lightweight corrugated cardboard, fundamentally altering the weight parameter while maintaining protective functionality. The cardboard construction with internal supports provides structural integrity at reduced weight, directly resolving the contradiction between packaging weight and handling ease.
2Loss of substance
If conventional 5-gallon plastic buckets are used, then the product is contained securely, but the packaging creates waste and landfill issues
Solution Approach 1:
The cardboard packaging is designed to be recyclable and biodegradable, enabling recovery and disposal without environmental harm. The internal plastic components are minimized and designed for separation, allowing the majority of the packaging to be composted or recycled, thus reducing landfill waste while maintaining containment reliability during use.
3Quantity of substance
If multiple 5-gallon buckets are purchased to cover large driveway areas, then sufficient product quantity is achieved, but handling and storage complexity increases
Solution Approach 1:
The patent merges multiple product units into a single large-format cardboard packaging container, eliminating the need for multiple separate buckets. This consolidation reduces handling complexity while providing sufficient product quantity for large driveway areas, directly addressing the contradiction between quantity and system complexity.
4Volume of stationary object
If conventional plastic buckets are used for distribution, then product protection is maintained, but packing density and storage efficiency decrease
Solution Approach 1:
The cardboard packaging utilizes thin-walled construction with strategic internal supports, reducing overall packaging volume compared to bulky plastic buckets. This allows more units to be stored in the same space, improving storage efficiency and productivity while maintaining adequate product protection through the corrugated cardboard structure.
Data Source
AI summary
An asphalt sealer packaging and dispensing system having a pre-portioned, modular containment for containing a volume of cold pour asphalt sealer. The modular containment is formed of a cube shaped outer corrugated cardboard housing having a high temperature stable sealing insert. The housing is interchangeably attached to a spreading apparatus having a wheeled carriage with grasping/pushing handles. A linear output of asphalt sealer is thereby dispensed as said wheeled carriage is rolled along a target surface.