Dual-End-Cap Bundle for Stacked Consumer Products
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for bundling consumer products, such as moist wipes pouches, face challenges in providing a cost-effective, aesthetically pleasing, and stackable solution that does not conceal product graphics, while also accommodating rigid flip-open lids and minimizing packaging material usage.
Innovation Solution
A dual-cap bundling system using a rigid substrate with end-caps and a bridge that connects them over the top face, allowing for partial visibility of the products and concealment of unsightly packaging, with the option to use a transparent flexible film for additional security and visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plastic film overwrap is used to bundle the stack, then the units are bundled together, but the resulting bundle lacks consistently flat surfaces making stacking and storage challenging
Solution Approach 1:
The invention uses a flexible plastic film that is selectively applied only to specific surfaces (end faces and selected lateral faces) rather than completely wrapping the stack. This partial application maintains the flexibility and simplicity of film bundling while creating flat surfaces on critical exterior faces for stable stacking and storage.
2Shape
If a cardboard box is used to provide flat surfaces, then stacking is improved, but the graphics on individual units are concealed and costs increase
Solution Approach 1:
The plastic film is applied selectively only to specific local areas (end faces and selected lateral faces) rather than completely enclosing the stack. This localized application provides flat surfaces where needed for stacking while leaving other areas exposed to maintain graphics visibility, thus resolving the contradiction between shaping needs and information preservation.
3Ease of manufacture
If gluing individual units together is attempted, then bundling is achieved, but the rigid flip-open lid prevents proper gluing
Solution Approach 1:
The flexible plastic film bundling method accommodates rigid flip-open lids by conforming to their shape and position on the pouch surfaces. The film can be applied over or around the rigid lids without requiring removal or modification, thus achieving bundling capability while maintaining adaptability to products with rigid closures.
4Strength
If a complete overwrap is used, then structural integrity is improved, but packaging material usage increases
Solution Approach 1:
The plastic film is applied selectively to specific surfaces (end faces and selected lateral faces) rather than completely wrapping all surfaces. This localized application provides structural integrity at critical locations where strength is most needed for handling and stacking, while minimizing material usage by not applying film to all surfaces.
Data Source
AI summary
A bundle of a stack of at least two consumer products is disclosed. The stack has opposite front and back faces spaced apart in a depth dimension, opposite top and bottom faces spaced apart in a height dimension, and opposite first and second end faces spaced apart in a length dimension. The bundle has a dual-cap bundling member that has a first end-cap that cups the stack at the first end-face, a second end-cap that cups the stack at the second end-face, and a bridge that integrally connects the first and second end-caps and that is superposed over the top face. The dual-cap bundling member is formed from a rigid substrate. The first end-cap and the second end-cap are not connected to each other via the rigid substrate other than by the bridge.