Composite Packaging Base for Recyclable Appliance Shock Protection
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Solution Overview
Problem
Existing packaging bases for household appliances face challenges in providing adequate mechanical strength, elasticity, protection against moisture, recyclability, and cost-effectiveness while being environmentally friendly, with complex designs increasing production costs.
Innovation Solution
A packaging base comprising a polypropylene tray, a wood panel, and a honeycomb paperboard with vertical honeycomb walls, designed for easy disassembly and recycling, offering mechanical strength, shock absorption, and moisture protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If expanded polystyrene is used for packaging base, then mechanical strength and elasticity are achieved, but recyclability deteriorates
Solution Approach 1:
The packaging base is divided into separate components: a reusable polypropylene tray and disposable cushioning elements made from biodegradable materials. This segmentation allows the tray to be recycled while the cushioning elements can be composted, resolving the recyclability issue while maintaining mechanical strength through the structured design of each component.
Solution Approach 2:
The patent transitions from using expanded polystyrene (a single material) to a composite structure with specific material parameters: polypropylene for the tray (reusable/recyclable) and natural fiber materials for cushioning (biodegradable). This parameter change maintains the required mechanical properties while improving environmental compatibility and recyclability.
2Reliability
If complex multi-element packaging base is used, then protection against impacts is improved, but production costs deteriorate
Solution Approach 1:
The patent combines multiple protective functions into integrated components. The tray structure itself provides both containment and structural support, while the cushioning elements are designed to absorb impacts through their material properties rather than through complex mechanical structures. This merging reduces the number of separate parts and simplifies manufacturing.
Solution Approach 2:
The cushioning elements are designed as disposable components made from inexpensive biodegradable materials. Rather than creating a complex reusable system, the patent uses simple, low-cost cushioning elements that can be easily replaced, reducing production costs while maintaining reliable impact protection through the disposable nature of these components.
3Weight of moving object
If expanded polystyrene is used for packaging base, then lightweight property is achieved, but environmental friendliness deteriorates
Solution Approach 1:
The patent changes the material parameters from expanded polystyrene to polypropylene for the tray structure. Polypropylene is heavier than EPS but is fully recyclable and environmentally friendly, resolving the conflict between lightweight property and environmental friendliness by prioritizing sustainability while maintaining acceptable weight characteristics.
Solution Approach 2:
The packaging base is designed with components that can be easily separated and recovered. The polypropylene tray can be recovered and recycled, while the cushioning elements made from natural fibers can be composted. This discarding and recovering approach eliminates the environmental harm of EPS while maintaining the lightweight advantage through the efficient use of materials.
4Ease of manufacture
If single-layer honeycomb paperboard is used, then production costs are reduced, but mechanical strength deteriorates
Solution Approach 1:
The patent uses composite materials construction for the cushioning elements, combining honeycomb paperboard structure with natural fiber materials. This composite approach provides the necessary mechanical strength while keeping production costs low, as the honeycomb structure offers high strength-to-weight ratio and the natural fibers provide cushioning properties without requiring expensive materials.
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 provides a lightweight, recyclable packaging base that absorbs shocks, protects against mechanical damage and moisture, and maintains low production costs by using simple, separable components.
Implementation Method 1
provides adequate mechanical strength, elasticity to absorb minor shocks and vibrations, and deforms plastically in the event of major impacts
Implementation Method 2
deforms plastically in the event of major impacts
Implementation Method 3
provides protection against ground moisture and possible water
Data Source
Figure 1~2
AI summary
The invention relates to a packaging base for household appliances such as a refrigerator, dishwasher, cooker, etc. The technical problem is how to provide a simple packaging base that has adequate mechanical strength, elasticity, capability to plastically deform is environmentally friendly and fully recyclable. The technical problem is solved by a packaging base (1) for household appliances, comprising: a polypropylene tray (2) comprising a quadrangular bottom (2a) and four peripheral lateral walls (2b) rising vertically from the bottom, a wood panel (3) arranged at the bottom of the tray so that it essentially fully covers the bottom of the tray, and at least a single-layer honeycomb paperboard (4) arranged in the tray over the wood panel and comprising a honeycomb core and two mutually parallel layers (4a) of paperboard glued to the honeycomb core (4b) on a respective side of the core, the honeycomb walls being oriented in a vertical direction.