Single-Layer Crepe Paper Enclosure for Conformal Protective Packaging
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Solution Overview
Problem
Current packaging materials are not recyclable, bulky, and require additional non-recyclable materials for protection, leading to increased shipping costs and environmental impact, with cardboard packaging compromising strength upon folding and failing to conform to item shapes.
Innovation Solution
A laminated packaging material with expandable layers, including a substrate layer and a cut-patterned layer, which can be expanded to form a customized enclosure, providing structural strength without additional fillers, and is fully recyclable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If cardboard packaging is used, then recyclability is improved, but protective strength is worsened when folded
Solution Approach 1:
The packaging material transitions from a static, rigid cardboard structure to a dynamic, expandable foam structure. The foam material can be compressed for shipping and then expands to provide superior protective strength, maintaining recyclability while solving the strength limitation of folded cardboard.
Solution Approach 2:
The invention changes the physical state and properties of the packaging material by using expandable foam that transitions from a compressed state to an expanded state. This parameter change enables the material to achieve high protective strength while maintaining a compact form for shipping and preserving recyclability.
2Productivity
If preformed cardboard boxes are used, then packaging speed is improved, but adaptability to item shapes is worsened
Solution Approach 1:
The packaging system uses dynamic expandable foam material that can adapt its shape and volume to match the item being packaged. The foam expands around the item, providing custom conformal protection without requiring preformed boxes, thus maintaining packaging speed while achieving superior adaptability.
Solution Approach 2:
The expandable foam material performs self-adjustment by expanding and conforming to the shape of the item automatically. This self-service capability eliminates the need for preformed boxes while maintaining efficient packaging, as the material adapts to any item shape without additional intervention.
3Strength
If additional protective materials are used with cardboard, then protective strength is improved, but material consumption is worsened
Solution Approach 1:
The invention merges the structural packaging function and the protective cushioning function into a single expandable foam material. This consolidation eliminates the need for separate protective materials, reducing overall material consumption while maintaining or improving protective strength through the integrated foam structure.
Solution Approach 2:
The expandable foam material undergoes a parameter change from compressed to expanded state, providing both structural support and protective cushioning in one material. This eliminates the need for additional protective materials, reducing material consumption while achieving adequate protection.
4Adaptability or versatility
If expandable packaging material is used, then adaptability to item shapes is improved, but device complexity is worsened
Solution Approach 1:
The invention uses flexible expandable foam material that can conform to any item shape. The flexibility and expandability of the foam simplify the packaging system by eliminating the need for complex preformed boxes or multiple components, achieving high adaptability with reduced overall system complexity.
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 expandable packaging material reduces material consumption, lowers costs, and minimizes environmental impact by conforming to item shapes, eliminating the need for additional protective materials and allowing for recycling.
Implementation Method 1
the first layer is pulled or extended in at least a first direction that is effective to the first layer to expand and additionally causes the second layer of the packaging material to expand
Data Source
AI summary
In an embodiment, a package can include a first creped paper packaging material, a second creped paper packaging material, and one or more shipping items. The first creped paper packaging material can include a first single-layer creped packaging paper. The second creped paper packaging material can include a second single-layer creped packaging paper. The first creped paper packaging material and the second creped paper packaging material can define a respective material perimeter, with the second creped paper packaging material being attached to the first creped paper packaging material proximal their respective material perimeters to form a set of bound borders. The first creped paper packaging material and the second creped paper packaging material can thereby be attached together in a manner to define a package enclosure. The one or more shipping items can be carried in the package enclosure.