Elastomer Bag Packaging with Support Structure to Reduce Consolidation Stress
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional packaging methods for bagged elastomer products lead to consolidation stress, causing deformation and loss of flowability due to static load, which is not adequately addressed by existing solutions like FIFO storage or anti-blocking coatings, and reducing shipment loads increases costs.
Innovation Solution
A packaging configuration featuring a pallet with a support structure having perpendicular sidewalls and a detachable top wall, creating an air gap between the top layer of bagged goods and the support structure, which reduces the stress on lower layers by transferring the weight of upper loads through vertical side panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If bagged elastomer products are stacked in conventional pallet configurations, then shipping efficiency is maintained, but consolidation stress causes deformation and blocking of pellets
Solution Approach 1:
A support structure acts as an intermediary element between the pallet and the bagged elastomer products. This support structure distributes the consolidation stress across a larger area and prevents direct compression of the pellets, thereby maintaining product quality while preserving shipping efficiency.
Solution Approach 2:
The invention introduces a vertical dimension to stress distribution by using a support structure with height. Instead of horizontal stacking alone, the support structure creates a three-dimensional configuration that elevates the bags off the pallet surface, reducing point-contact stress and preventing pellet blocking through spatial separation.
2Object-affected harmful factors
If anti-blocking coatings are applied to polymer pellets, then blocking is reduced, but production costs increase due to additional materials
Solution Approach 1:
The support structure serves as a physical intermediary that prevents pellet-to-pellet contact and deformation, eliminating the need for chemical anti-blocking coatings. This mechanical solution achieves the same protective function without adding material costs to pellet production.
Solution Approach 2:
The invention replaces the chemical approach (anti-blocking coatings) with a mechanical approach (support structure). By using physical support and spatial separation, the system achieves blocking prevention through mechanical means rather than chemical modification, reducing production costs.
3Object-affected harmful factors
If reduced loads or half-filled boxes are used, then consolidation stress is minimized, but shipping and packaging costs increase significantly
Solution Approach 1:
The support structure enables full-load shipping by adding a vertical dimension to stress management. Bags are positioned upright on the support structure rather than flat stacking, allowing maximum utilization of shipping space while maintaining reduced consolidation stress through the elevated configuration.
Solution Approach 2:
The support structure segments the stacking configuration into distinct levels - the support structure base and the elevated bag position. This segmentation allows for optimized weight distribution and stress reduction while maintaining full shipping capacity, avoiding the need for reduced loads.
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 configuration significantly reduces consolidation stress on lower layers of bagged goods, minimizing massing and blocking, while maintaining shipping efficiency without the need for additional materials or increased costs.
Implementation Method 1
A packaging configuration which includes a pallet, a first stack of bagged goods stacked on the pallet, and a support structure situated over the first stack of bagged goods... wherein the support structure has at least four walls, and wherein one of the walls is a top wall, and wherein at least three of the walls are sidewalls that are each, independently, in a perpendicular orientation to the top wall
Data Source
AI summary
Packaging configuration comprising: a pallet comprising a top surface, a bottom surface and a height HP; a first stack of bagged goods having a total height HL1, stacked on the pallet and comprising at least two layers; and a support structure comprising at least four walls situated over the first stack of bagged goods, one of the walls being a top wall and at least three of the walls being sidewalls. The support structure has a height HC that meets one of the following equations: HC>HL1, when the bottom end of at least one sidewall of the support structure is positioned on the top surface of the at least one pallet; or HC>HP+HL1, when the bottom end of at least one sidewall of the support structure and the bottom surface of the pallet are both positioned on the same surface. An air gap having a height HAG is situated between a top layer of the first stack of bagged goods and the top wall of the support structure.