Custom Packaging with Air Gap and Vents for Automated Protection

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Solution Overview

Problem

Existing packaging technologies lack flexibility in design and manufacturing, making it difficult to automate secondary packaging and ensure proper fit and protection for primary packages during shipping, especially in distribution centers.

Innovation Solution

A recyclable plastic film-based package manufacturing system that allows for real-time creation of custom packaging with an air gap between inner and outer packages, using vents to control air movement and pressure, enabling faster, more reliable, and consumer-friendly packaging solutions that can be automated in-line during production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional packaging materials like Styrofoam peanuts or air-filled plastic bags are used, then protection is provided, but manufacturing flexibility and automation capability are reduced

Engineering Contradiction:

ImproveprotectionVSAvoidmanufacturing flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent uses a flexible plastic film bag as the packaging structure that can be automatically formed and sealed around products. This thin film material provides adequate protection while enabling full automation capability, replacing rigid Styrofoam peanuts and complex air-filled bag systems with a simple, formable film that can be processed by automated machinery.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent replaces manual or semi-automated packaging processes with a fully automated system that uses mechanical forming, sealing, and cutting mechanisms. The plastic film is automatically formed around the product, sealed at the top, and excess material is cut away, eliminating the need for manual placement of protective materials and enabling integration with automated production lines.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Stability of the object's composition

If predetermined design and fabrication processes are used for primary and secondary packages, then packaging structure is established, but real-time customization and in-line automation are hindered

Engineering Contradiction:

Improvepackaging structureVSAvoidreal-time creation capability

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The patent transforms the packaging process from a static, predetermined assembly of pre-made boxes and spacers into a dynamic, real-time forming process. The plastic film is continuously formed, filled, sealed, and cut in-line with product movement, allowing the packaging structure to be created on-demand rather than pre-fabricated, thereby enabling both structural stability and real-time customization.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent performs preliminary actions by pre-forming the plastic film bags and preparing sealing and cutting mechanisms before product arrival. This allows the packaging process to proceed smoothly in-line without delays, as all necessary components and operations are prepared in advance but executed in real-time as products move through the system.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If automated packaging manufacturing is implemented, then production speed increases, but flexibility in package design and formatting is reduced

Engineering Contradiction:

Improvepackaging speedVSAvoidpackage design flexibility

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent employs a universal plastic film packaging system that can accommodate various product sizes, shapes, and types through a single automated forming and sealing process. The same basic mechanism can handle different packaging requirements by adjusting film dimensions and sealing parameters, providing both high-speed automation and design flexibility without requiring multiple specialized systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This solution provides improved shipping performance, additional protection, and ease of opening, while allowing for custom package creation and balancing atmospheric pressures, enhancing the flexibility and efficiency of packaging processes.

Implementation Method 1

Air may be used as a protective cushion between inner and outer forms

Methodology Applied

Scientific EffectAir cushioning: Compression

Implementation Method 2

A vent may be used to allow limited air movement without impacting protection

Methodology Applied

Scientific EffectPressure equalization: Pressure Gradient

Data Source

PatentUS11492187B2Custom packaging and process for forming the custom packaging

Publication Date: 2022.11.08 HOLLYMATIC CORP

AI summary

A package and a method of forming the package, the package including a primary package; an inner package provided around the primary package; an outer package provided around the inner package and the primary package, such that an air gap is formed between the inner package and the outer package, the outer package including two bodies that are configured to surround opposite sides of the inner package, respectively; and a tape configured to seal the two bodies of the outer package together.