Conformable Corrugated Mailer Structure for Recyclable Space-Saving Shipping
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Solution Overview
Problem
Existing shipping containers are not recyclable and require manual separation of components, leading to improper disposal, and larger containers occupy excessive storage and shipping space, necessitating the use of filler materials.
Innovation Solution
A conformable recyclable shipping container made of two panels with paper outer liners and corrugated medium, featuring score lines and side edge extensions for flexible conformation to objects, reducing thickness and increasing shipping density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a larger mailer is used to accommodate different products, then product protection is improved, but storage space and shipping space are increased
Solution Approach 1:
The mailer panels are designed with score lines that allow them to be dynamically folded and bent into different configurations. The panels can be manipulated to conform to various product shapes and sizes, transforming the mailer from a fixed-size container to an adaptable packaging solution that optimizes space for different products.
Solution Approach 2:
The mailer uses thin corrugated paper panels with score lines that enable flexibility and conformability. These flexible panels can be bent and shaped to wrap around different product geometries, providing protection while maintaining a compact form that minimizes storage and shipping volume.
2Reliability
If a mailer larger than necessary is used, then product protection is improved, but dead spaces are created allowing product movement
Solution Approach 1:
The flexible corrugated panels can be bent and folded to conform precisely to the product's shape, eliminating dead spaces and gaps that would otherwise require filler material. The panels wrap around the product tightly, providing protection while maintaining full utilization of the mailer's internal volume.
3Productivity
If empty shipping containers are stored in large quantities, then shipping readiness is improved, but storage space for empty containers is increased
Solution Approach 1:
The mailers are designed in a flat, collapsed state for storage, minimizing the volume occupied by empty containers. When needed, the panels can be quickly unfolded and configured into the required shape and size, providing shipping readiness without requiring large quantities of pre-assembled containers to be stored.
4Reliability
If bubble mailers made of multiple components are used, then product protection is improved, but recyclability is worsened due to manual separation requirements
Solution Approach 1:
The mailer is constructed from a single homogeneous material - corrugated paper - rather than multiple different materials like plastic and paper combined. This single-material construction maintains product protection while enabling straightforward recyclability through standard paper recycling processes without requiring manual separation of components.
Data Source
AI summary
A shipping container made of two panels each made of recyclable, single face corrugated paper comprising an outer liner with corrugated medium. In one embodiment, the panels are formed from a large blank that is folded in half and joined at their side edges. The flutes on the corrugated mediums are parallel and longitudinally aligned with the shipping container's longitudinal axis. The top edge of each panel is detached and form a top opening into an interior pocket formed between the two panels. Formed or attach to one panel is a top flap configured to be folded over and selectively attached to the opposite panel to close the top opening. Formed on each corrugated medium is at least one set of score lines of various geometric shapes and orientations. The score lines act as folding lines that enable the panels to bend along different axes so that the overall shape of the shipping container better conforms to the object placed in the interior pocket. The sizes of flutes on each panel may be the same size or vary in size. The flutes on opposite panels may be axially aligned or offset. Improved side edges attachment features are provided that reduce side edge separation and reduce thickness.