Expandable Packaging Web for Compact Shipping and On-Site Cushioning
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Solution Overview
Problem
Traditional protective packaging is produced in bulky, low-density configurations, leading to increased shipping costs and reduced storage capacity due to its volume before use.
Innovation Solution
A method for producing packaging material in a low volume, high-density configuration that can be expanded at a later time using a matrix and expansion element, which are combined and activated to form an expanded wall providing padding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If protective packaging is produced in bulky, low-density configurations, then packaging support during shipment is provided, but shipping costs increase and storage capacity decreases
Solution Approach 1:
The packaging material is prepared in advance in a compact, unexpanded state with expansion elements embedded within a matrix structure. The actual expansion action is performed preliminarily at the shipping location rather than during production and transport, allowing the material to occupy minimal space during logistics while providing full protective function when needed.
Solution Approach 2:
The packaging material undergoes a parameter change from a compact, high-density unexpanded state to an expanded, low-density protective state. This transformation is achieved through activation of expansion elements that cause the matrix to increase in volume, thereby providing the same protective function with reduced transport volume.
2Ease of operation
If packaging material is transported in expanded configuration, then immediate use is possible, but shipping costs increase and storage efficiency decreases
Solution Approach 1:
The packaging material is prepared in advance in a compact, unexpanded state with all necessary components (matrix and expansion elements) in place. The expansion action is deferred to the point of use, eliminating the energy cost of transporting expanded material while ensuring immediate functionality when activated.
3Reliability
If traditional protective packaging is produced in bulky configurations, then cushioning protection is provided, but storage capacity at packaging locations decreases
Solution Approach 1:
The packaging material utilizes a parameter change from compact unexpanded state to expanded protective state. This allows the same quantity of material to provide equivalent cushioning protection while occupying significantly less space during storage and transport, thereby increasing the quantity of packaging material that can be stored at given locations.
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
Reduces shipping costs and increases storage capacity by allowing packaging material to be compactly transported and expanded on-site, providing effective cushioning for shipped items.
Implementation Method 1
the expansion element causes the matrix to expand, thereby increasing the spacing between the first and second plies
Implementation Method 2
the matrix is selected to solidify upon activation of the expansion element to provide the solidification of the expansion material
Data Source
Figure 1
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AI summary
A method for making an expansion wall is provided. The method can include applying a matrix to a first ply and applying an expansion element to the surface of the matrix. A second ply is applied over the first ply to trap the matrix and expansion element therebetween. The applied expansion element is entrained into the applied matrix to provide an expansion material that is configured to expand to, and solidify in, an expanded condition upon activation.