Expanding Flat-Stock Paper Into Interlocking Packing Elements
Solution Overview
Problem
Existing paper packing materials, such as expanded foam and plastic bubble wrap, are not environmentally friendly and inefficient in terms of storage space, whereas paper-based packing elements are desirable for their eco-friendliness and recyclability, but require effective methods to expand flat-stock paper precursors into usable packing materials.
Innovation Solution
A system and method for expanding flat-stock paper precursors into triangular packing elements using a machine with pivotable jaws, gears, and a cam mechanism, which folds and separates the paper to create serrated edges for interlocking and maintains the shape with connecting features, allowing for efficient production of expanded packing elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If non-paper based packing materials such as expanded foam or plastic bubble wrap are used, then protection effectiveness is improved, but environmental friendliness deteriorates
Solution Approach 1:
The invention changes the material parameter from non-paper (foam, plastic) to paper-based material, achieving environmental friendliness while maintaining protection effectiveness through structural design of the expanded packing element with interlocking flaps and connecting features
2Strength
If pre-formed packing materials such as packing peanuts are used, then protection effectiveness is improved, but storage space efficiency deteriorates
Solution Approach 1:
The invention segments the packing material into flat-stock precursor sheets that can be stored compactly, then expands them into three-dimensional packing elements with multiple flaps and connecting features that provide effective protection, achieving both storage efficiency and protection effectiveness
Solution Approach 2:
The flat-stock precursor material can be stored in a nested, compact form, and when expanded, forms a larger three-dimensional structure that provides protection, similar to the nested doll principle where a small object transforms into a larger functional form
3Volume of stationary object
If flat-stock paper precursors are stored, then storage space efficiency is improved, but production efficiency deteriorates without effective expansion methods
Solution Approach 1:
The invention prepares the paper precursor material in advance in a flat-stock form with pre-scored lines and connecting features, enabling rapid expansion into packing elements through simple folding and interlocking actions, thus improving production efficiency
Solution Approach 2:
The invention introduces a dynamic expansion mechanism where flat-stock precursors are transformed into three-dimensional packing elements through controlled folding and interlocking of flaps, enabling efficient production through mechanical movement and transformation
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
A base has an end plate adapted to rotate about an axis substantially orthogonal to the base. A first jaw extends from the end plate and is pivotably engaged with the end plate. As the end plate rotates about the axis, the first jaw defines a first separation angle when the end plate is at a first position and the first jaw defines a second separation angle when the end plate is at a second position.