Crush Resistant Packaging Material With Customizable Fit
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Solution Overview
Problem
Conventional packaging materials, such as corrugated fiberboard boxes and cushioned mailers, face issues with size customization, material waste, and inadequate protection for fragile items, leading to increased shipping costs and environmental impact.
Innovation Solution
A packaging material comprising a structural assembly with a core and stiffening portion, attached via adhesive or mechanical means, that can be tailored to fit items securely, providing enhanced crush resistance and flexibility, reducing material usage and waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If standard corrugated fiberboard boxes are used, then crush resistance is provided, but size customization is limited and material waste increases
Solution Approach 1:
The patent uses a flexible packaging material that can be wrapped around items of various sizes and shapes, eliminating the need for standard rigid boxes. The material is applied in a continuous wrap format that adapts to the contours of the contained item, providing custom fit for each package size while maintaining structural integrity and crush resistance throughout the shipping process.
Solution Approach 2:
The packaging material combines multiple functional layers including a flexible outer layer, a cushioning layer with void spaces for impact absorption, and an inner lining layer. This composite structure integrates the benefits of different materials to achieve both customization flexibility and protective strength, allowing the same material to serve various package size requirements effectively.
2Reliability
If boxes that are too large are used, then items are protected from jostling, but shipping costs increase and material waste occurs
Solution Approach 1:
The flexible wrap material conforms precisely to the dimensions and shape of the contained item, creating a custom-fitting package that eliminates excessive empty space. This precise fit reduces the volume of packaging material required while still providing adequate protection during shipping, thereby reducing both material waste and shipping costs associated with oversized boxes.
Solution Approach 2:
The packaging material incorporates a cushioning layer with engineered void spaces that are distributed throughout the wrap structure. This pre-positioned cushioning provides protection against jostling and impact from the outset, eliminating the need for additional filler materials and ensuring item safety without requiring excessive packaging volume.
3Ease of operation
If cushioned mailers are used, then protection is provided, but adequate protection for fragile items is not achieved
Solution Approach 1:
The packaging material employs a multi-layer composite structure where the outer layer provides flexible containment, the intermediate cushioning layer with void spaces absorbs impact forces, and the inner lining layer provides direct contact protection. This layered composite design achieves superior protection for fragile items compared to single-layer cushioned mailers, combining the ease of use of a simple wrap application with enhanced protective performance.
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 packaging material offers customizable size options, improved protection for fragile items, reduced material usage, and lower shipping costs, while maintaining environmental sustainability.
Implementation Method 1
a first attachment portion (110, 120) adjacent to a core portion (140) adjacent to a stiffening portion (160) adjacent to a second attachment portion (110, 120)
Data Source
AI summary
The present disclosure relates to crush resistant packaging materials and/or constructions and to methods of making and using them. Many embodiments provide crush resistance in addition to customizability.