Carrier Insert with Form-Fitting Padding for Package Protection
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Solution Overview
Problem
Existing carrier inserts for shipping packaging lack effective protection against mechanical damage, particularly for sensitive devices and components, as they either fail to prevent surface damage or are material-intensive and expensive, while also requiring high stability and ease of use.
Innovation Solution
The development of carrier inserts comprising a stable frame substructure with edge-crush-resistant materials and damping padding elements, featuring pegs or recesses for a form-fitting connection, which provides both static and dynamic load capacity and can be easily adapted for repeated use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If toothed strips made of corrugated cardboard or wood are used, then the carrier insert provides structural support, but the hard faces cause surface damage and impact damage to parts
Solution Approach 1:
The invention combines rigid surface elements made of corrugated cardboard or wood with soft padding elements made of foam material. This composite structure provides both structural support from the rigid elements and protection against surface damage and impact from the soft padding elements, resolving the contradiction between strength and harmful effects.
2Object-affected harmful factors
If foam and plastic toothed strips are used, then surface damage and impact damage are prevented, but the carrier insert becomes material-intensive and expensive
Solution Approach 1:
Instead of using foam or plastic throughout the entire carrier insert, the invention applies padding elements only at specific locations where parts contact the structure. This localized approach provides necessary protection against surface damage and impact while significantly reducing overall material consumption and cost.
Solution Approach 2:
The carrier insert combines inexpensive rigid materials (corrugated cardboard or wood) for structural support with minimal amounts of soft foam material only where needed for protection. This composite approach achieves effective protection while maintaining cost-effectiveness and reducing material intensity.
3Object-affected harmful factors
If full-surface materials with recesses are used, then parts are protected, but the packaging becomes heavy and less stable
Solution Approach 1:
The invention divides the carrier insert into separate rigid surface elements and separate padding elements. This segmentation allows the rigid elements to provide structural stability and support, while the padding elements provide localized protection. The modular design prevents the packaging from becoming heavy and unstable.
4Object-affected harmful factors
If padding parts made of foam material are detachably arranged on a holding plate, then protection is provided, but the carrier insert requires more complex assembly and is less suitable for repeated use
Solution Approach 1:
The invention merges the padding elements directly with the rigid surface elements by inserting the padding elements into recesses of the surface elements. This integration creates a unified, pre-assembled carrier insert structure that is simple to manufacture and highly suitable for repeated use, eliminating the need for complex detachable assemblies.
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
The solution offers lightweight, cost-effective protection against mechanical damage, combining high edge crush resistance with impact and vibration protection, allowing for efficient reuse by replacing worn padding elements, thus reducing material usage and maintenance costs.
Implementation Method 1
damping padding elements
Implementation Method 2
protection against mechanical damage... impact and vibration protection
Implementation Method 3
frame substructure consists of at least two surface elements arranged on edge and spaced apart with high edge crush resistance
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The insert has pad units (2) on which parts to be transported are supported. A stable framework sub-structure has two upright planar units (1) arranged at a specific distance. Front sides of the units possess partly the shape of received packing parts, and the pad units lie on the front sides. The pad units have taps (3) or recesses formed at a frame side, and the planar units have recesses (4) or tap corresponding to the taps or recesses of the pad units. The structure has transversely arranged auxiliary planar units (5) which are arranged in single sided or double-sided arranged slots (7).