Co-Packaged Blister Pack Protrusion Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Thermoformed blister packs for large-scale production typically have limited strength and rigidity due to manufacturing costs associated with using more rigid materials or thicker plastic sheets, which can lead to compromised structural integrity and increased risk of damage or pilferage when bundling multiple products together.
Innovation Solution
A co-packaged article design featuring inner and outer flange members with protrusions that limit inward and outward flexing, along with a label that interconnects the cavities to enhance structural integrity, allowing for the use of weaker materials while maintaining rigidity and preventing distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thinner materials are used for thermoforming, then manufacturing costs are reduced and environmental impact is minimized, but the structural integrity and rigidity of the blister pack deteriorate
Solution Approach 1:
The blister pack is divided into multiple cavities separated by internal walls with protrusions. These protrusions create discrete structural zones that independently reinforce each cavity, allowing the use of thinner overall material while maintaining local rigidity where needed for structural integrity.
Solution Approach 2:
The internal walls contain protrusions that provide localized reinforcement at specific points within the cavities. This concentrates structural strength where most needed (at cavity boundaries and product support points) while allowing thinner material in less critical areas, optimizing the balance between cost and strength.
2Strength
If thicker plastic sheets or more rigid materials are used, then the strength and rigidity of the blister pack are improved, but manufacturing costs increase
Solution Approach 1:
Instead of using uniformly thick or rigid material throughout, the structure is segmented into cavities with internal walls containing protrusions. This segmentation provides rigidity only where structurally necessary, eliminating the need for expensive thick material in entire packages.
Solution Approach 2:
The design changes the structural parameters by adding geometric features (protrusions) rather than simply increasing material thickness. This achieves rigidity through shape optimization rather than material quantity, reducing manufacturing costs.
3Productivity
If multiple products are bundled together in a single pack, then packaging costs are reduced and consumer value is increased, but the risk of damage and pilferage increases due to compromised structural integrity
Solution Approach 1:
Multiple products are placed in separate cavities within a single pack, with internal walls containing protrusions providing structural reinforcement. This segmentation allows efficient bundling of multiple items while the reinforced structure prevents the pack from becoming too flexible or vulnerable to damage and pilferage.
Solution Approach 2:
The pack combines multiple functional elements (cavities, internal walls, protrusions, labels) into a composite structure that provides both the flexibility needed for bundling multiple products and the rigidity required for protection against damage and pilferage.
4Strength
If protrusions are added to internal walls to limit flexing, then rigidity is improved, but device complexity increases
Solution Approach 1:
The internal walls are segmented with protrusions that create discrete reinforcement zones. This segmentation provides rigidity through simple geometric additions rather than complex overall structural changes, maintaining manufacturability while improving strength.
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 design provides increased rigidity and structural integrity, preventing damage during shipping and handling, while allowing for thermoforming with thinner materials, thus reducing costs and environmental impact, and enhancing consumer perception of product quality.
Implementation Method 1
The protrusion is spaced apart from the first internal wall in the first position and contacts the first internal wall in the second position limiting inward flexing of the first and second cavities toward each other
Implementation Method 2
A label interconnects the first and second cavities limiting outward flexing of the first and second cavities
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A pack (12) for a co-packaged article (12) with an inner flange member (19) and an outer flange member (16). A first cavity (20) is defined by the inner flange member and the outer flange member. The first cavity has an outer surface (22) and a first internal wall (25). A second cavity (30) is defined by the inner flange member and the outer flange member. The second cavity has an outer surface (32) and a second internal wall (35) spaced apart from the first internal wall. The second internal wall has at least one protrusion (36) with a first position and a second position. The protrusion (36) is spaced apart from the first internal wall (25) in the first position and contacts the first internal wall in the second position limiting inward flexing of the first and second cavities (20, 30) toward each other.