Dual-Layer Packaging for Compact Light Assemblies

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Solution Overview

Problem

Compact light assemblies are prone to unintended activation due to rough handling during shipping and handling, leading to battery waste and consumer complaints, and can inadvertently reveal the user's location during tactical operations.

Innovation Solution

A dual-layer packaging system comprising a soft, energy-absorbing inner package made of foamed plastic or similar material and a protective outer package, designed to prevent accidental activation and physical damage, with the inner package allowing for easy carrying and deployment of multiple light assemblies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If light assemblies are loosely packaged in bulk in plastic bags and cardboard boxes for easy storage and shipping, then storage and shipping convenience is improved, but the light assemblies are prone to unintended activation due to rough handling and bumping

Engineering Contradiction:

Improvestorage and shipping convenienceVSAvoidunintended activation prevention

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The packaging system is divided into two distinct layers: an inner package that directly contacts and protects the light assembly, and an outer package for bulk storage and shipping. This segmentation allows the inner package to provide precise protection against activation while the outer package maintains shipping convenience.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The inner package is designed with cushioning materials that absorb impact and prevent the light assembly from bumping against hard surfaces during shipping and handling. This beforehand cushioning prevents unintended activation of the on-off switch while maintaining the convenience of bulk packaging.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Ease of operation

If light assemblies are carried loosely in a pocket for easy access and portability, then ease of carrying is improved, but the light assembly can be accidentally activated by bumping against hard surfaces

Engineering Contradiction:

Improveease of carryingVSAvoidaccidental activation

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The light assembly is nested within the inner package, which itself is contained within the outer package. This nested structure allows the light assembly to be easily carried in a pocket while maintaining protection against accidental activation through the protective layers.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The inner package acts as an intermediary between the light assembly and the external environment (including the pocket and hard surfaces). This intermediary layer prevents direct contact between the light assembly and activating forces while maintaining ease of carrying.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If a protective inner package is introduced to prevent accidental activation and physical damage, then reliability is improved, but the packaging complexity increases

Engineering Contradiction:

Improveprotection against accidental activationVSAvoidpackaging structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The packaging system is segmented into two functional layers with distinct roles: the inner package for protection and the outer package for shipping and storage. This segmentation simplifies the overall design by assigning specific functions to each layer, avoiding the need for a single complex multi-functional package.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The inner package serves multiple functions simultaneously: it protects the light assembly from accidental activation, provides physical cushioning against damage, and enables easy carrying. This multi-functionality reduces the need for additional separate protective elements, thereby limiting the increase in overall complexity.

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

The packaging system effectively prevents unintended activation and physical damage, ensuring battery life conservation and maintaining user stealth, while allowing convenient and secure carrying of multiple light assemblies.

Implementation Method 1

A soft, energy-absorbing inner package made of foamed plastic or similar material

Methodology Applied

Scientific EffectEnergy absorption through deformation: Deformation

Data Source

PatentUS9221594B2Packaging for compact light assemblies

Publication Date: 2015.12.29 BUSHEE GLENN

AI summary

A system is disclosed for minimizing damage to a compact light assembly having a battery, a light and an on-off switch. An outer package snugly holds an inner package formed with a series of spaced-apart slots. A light assembly is snugly frictionally held in each slot to protect the light assembly from damage due to shipping and/or rough handling. The packaging system also prevents the unintended activation of the on-off switch due to rough handling.