Compressible Packaging Assembly for Dimensional Weight Reduction

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Solution Overview

Problem

Shipping companies face high costs due to the dimensional weight pricing method, which charges based on the volume of empty, fully erected shipping containers, even when they are not filled with goods, leading to increased costs for customers returning items like electronics.

Innovation Solution

A compressible packaging assembly that includes a foldable outer shell and compressible cushioning material, allowing the container to be reduced in size when empty, thus lowering its dimensional weight and shipping costs, and easily expanded for item insertion and shipping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If a shipping container is fully erected and empty, then it provides adequate space for items, but it occupies large volume resulting in high dimensional weight and shipping costs

Engineering Contradiction:

Improvevolume of shipping containerVSAvoidshipping cost

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The shipping container is designed to be dynamically changeable between two states: fully erected for item placement and compressed for shipping. The container includes collapsible walls and a compressible base that allow it to transition from a large volume state to a compact state, enabling the system to adapt its volume based on operational needs rather than being fixed in one configuration.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The container structure is segmented into multiple collapsible components including side walls, end walls, and a compressible base. These segments can be independently folded or collapsed to reduce the overall volume of the container when not in use, allowing it to be shipped in a compact form while maintaining full functionality when erected.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If a shipping container is compressed to reduce volume, then shipping costs decrease, but the container must be easily expandable for item insertion

Engineering Contradiction:

Improveshipping costVSAvoidease of expansion

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The container is pre-assembled in a compressed state for efficient shipping, and the design incorporates pre-configured expansion mechanisms such as collapsible walls with hinge joints and a pre-formed compressible base. These preliminary configurations allow the container to be quickly and easily expanded to its full size for item insertion without requiring complex assembly procedures.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The container utilizes flexible collapsible walls made from bendable materials that can be folded inward to compress the container volume. These flexible walls can be easily unfolded and secured to restore the full container volume, providing a simple and effective mechanism for transitioning between compressed and expanded states.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If cushioning material is included in the container, then item protection is improved, but the container volume increases when empty

Engineering Contradiction:

Improveitem protectionVSAvoidcontainer volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The cushioning material is designed with compressible properties that allow it to change its volume based on the container's state. When the container is compressed for shipping, the cushioning material compresses along with it, maintaining its protective function while minimizing the overall volume. When the container is expanded for use, the cushioning material expands to provide adequate protection for items.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The container combines rigid structural components with compressible cushioning materials to create a composite packaging system. The rigid walls provide structural integrity when erected, while the compressible cushioning material (such as foam or air-filled chambers) provides protection and can be compressed to reduce the overall volume when the container is not in use.

Inventive Principle:

Principle #40Composite 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 compressible packaging assembly significantly reduces shipping costs by occupying a smaller volume when empty, allowing it to be shipped at a lower rate while still providing adequate protection for items during transport.

Implementation Method 1

the cushion materials are compressed from their free shape into a compressed state such that the assembly occupies a first volume of space

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

The assembly is configured to be folded into a compressed state

Methodology Applied

Scientific EffectFolding: Folding

Data Source

PatentUS9199761B2Compressible packaging assembly

Publication Date: 2015.12.01 MCDONALD JOHN

AI summary

A packaging container can be configured to include cushioning material and to be foldable between an expanded state in which the container can be used to ship an article and a compressed state in which the container occupies a smaller volumetric space without the article being contained therein. This can reduce shipping costs associated with transporting the empty container.