Expandable Packaging Material with Cut-Patterned Layers

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Solution Overview

Problem

Current packaging materials are not recyclable, are often bulky, and require additional non-recyclable materials for protection during shipping, leading to increased environmental impact and costs.

Innovation Solution

A fully recyclable packaging material comprising multiple layers that can be expanded in real-time to form customized enclosures, eliminating the need for additional protective materials by providing structural strength and conforming to the shape of the item, thus reducing material consumption and waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional packaging materials are used, then items can be protected during shipping, but the packaging is not recyclable and increases environmental impact

Engineering Contradiction:

Improveprotection during shippingVSAvoidenvironmental impact

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The packaging material changes its physical parameters by expanding from a compressed state to an expanded state, transforming from a space-efficient form to a protective form. This parameter change allows the same material to serve different functions at different stages, reducing overall material consumption and environmental impact while maintaining protection reliability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The packaging employs a composite structure with multiple layers including an expandable layer and a non-expandable layer bonded together. This composite design combines the space-efficient compressed state of the expandable layer with the structural stability of the non-expandable layer, achieving both environmental benefits and reliable protection.

Inventive Principle:

Principle #40Composite materials

2Object-generated harmful factors

If cardboard packaging is used, then the packaging is recyclable, but the strength is compromised when folded and additional protective materials are required

Engineering Contradiction:

ImproverecyclabilityVSAvoidstructural strength

Core Design Contradiction:

Object-generated harmful factorsVSStrength

Solution Approach 1:

The packaging material transitions from a static folded state to a dynamic expanded state, where the expandable layer unfolds to provide structural strength. This dynamic transformation allows the material to gain strength when needed for protection while maintaining recyclability, eliminating the need for additional protective materials.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The composite structure combines an expandable layer with a non-expandable layer, where the expandable layer provides structural strength when unfolded while the non-expandable layer maintains structural integrity. This composite design achieves both strength and recyclability without requiring additional protective materials.

Inventive Principle:

Principle #40Composite materials

3Strength

If preformed boxed packaging is used, then items can be protected, but the packaging does not conform to the shape or size of the item and requires additional packaging material

Engineering Contradiction:

ImproveprotectionVSAvoidmaterial consumption

Core Design Contradiction:

StrengthVSLoss of substance

Solution Approach 1:

The packaging material dynamically adapts its shape and size by expanding from a compressed state to an expanded state that conforms to the item being packaged. This dynamic adjustment eliminates the need for additional protective materials while maintaining adequate protection, reducing overall material consumption.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The packaging material changes its physical parameters including volume, shape, and dimensions when expanding, allowing it to conform precisely to the item being packaged. This parameter change enables the packaging to provide adequate protection without requiring additional materials, reducing waste.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If additional protective materials are added, then item protection is improved, but shipping costs and environmental impact increase

Engineering Contradiction:

Improveitem protectionVSAvoidpackaging material quantity

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The packaging material dynamically expands to provide adequate protection without requiring additional protective materials. The expandable layer unfolds to create the necessary protective structure, reducing the total quantity of packaging material needed while maintaining reliable item protection and lowering shipping costs.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The packaging material changes its volume and physical dimensions by expanding, providing sufficient protection with a single material type rather than requiring multiple layers of packaging. This parameter change reduces the quantity of substance needed while maintaining protection reliability.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20240181764A1Packaging material having expandable layers

Publication Date: 2024.06.06 IOW LLC

AI summary

A packaging material including one or more expandable layers that provide protection to contents of a packaging enclosure formed with the packaging material. The packaging material includes at least a first layer and a second layer bonded to one another. The first layer is pulled or extended in a first direction that is effective to cause the second layer to expand in a second direction. The second layer is a cut-patterned layer which increases in thickness and provides structural strength to the packaging material when expanded.