Flat Article Packaging with Loop-Wound Straps and Cut Flaps
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Solution Overview
Problem
Existing methods for packing flat articles, such as ceramic tiles, face challenges with large dimensions due to difficulties in folding and adjusting blanks, leading to damage and inefficient use of storage space, and require multiple formats and excessive glue, which complicates handling and protection during storage and transport.
Innovation Solution
A method using loop-wound straps and adhesive means to stabilize the superposing zones of packing blanks, with strategically placed cut lines and flaps to create a protective 'U'-shaped package that reduces material and glue usage, allowing for effective protection of flat articles and edges without the limitations of traditional methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional folding blanks are used for packing large dimension tiles, then the tiles can be protected during transport, but the blanks become extremely difficult to fold and adjust, and may damage the tiles
Solution Approach 1:
The blank is divided into multiple flaps (first lateral flaps, second lateral flaps, first folds, second folds) that can be independently folded and positioned. This segmentation allows each flap to be separately manipulated, making the packing process easier and reducing the risk of damage during folding operations.
Solution Approach 2:
The blank is pre-configured with specific fold lines and flap arrangements before use. The crease lines and fold structures are predetermined, allowing the blank to be easily folded into the correct configuration without complex adjusting during the packing process.
2Device complexity
If single format blanks are used for packing, then the structure is simple, but multiple blank formats are required to accommodate different tile formats
Solution Approach 1:
The blank design with its multiple flaps and fold lines can accommodate various tile formats and sizes using a single blank type. The flaps can be adjusted and positioned differently depending on the tile dimensions, making the blank universal for packing different formats without requiring multiple specialized blank designs.
Solution Approach 2:
The blank structure includes movable flaps and folds that can be dynamically adjusted during the packing process. The first and second lateral flaps can be folded in different configurations, and the folds can be positioned at different locations, allowing the same blank to adapt to various tile formats dynamically.
3Loss of substance
If thin blanks are used to reduce material usage, then material consumption is reduced, but the blanks are prone to damage during folding operations
Solution Approach 1:
The blank design incorporates multiple overlapping flaps and folds that create a cushioning effect during folding. The layered structure of the flaps distributes stress and protects the thin blank material from damage during the folding process, allowing thin blanks to be used without compromising durability.
Solution Approach 2:
The blank is designed as a flexible structure with multiple thin flaps and folds that can bend and conform during packing. The flexibility of the thin material allows it to be folded without breaking, while the multiple layers provide sufficient strength and protection when properly configured.
4Stability of the object's composition
If excessive glue is used to secure the blank, then the package stability is improved, but the environmental impact and cost increase
Solution Approach 1:
The blank structure is designed to self-stabilize through its own geometry and folding configuration. The overlapping flaps and folds create inherent mechanical interlocking and friction that secures the package without requiring excessive glue. The structure serves itself to maintain stability through its design rather than relying heavily on adhesive substances.
Solution Approach 2:
The folding lines and flap configurations create curved and angled surfaces that interlock mechanically. The angled folds and overlapping flaps generate friction and mechanical resistance that stabilizes the package structure, reducing the need for glue compared to flat, planar joining surfaces.
Data Source
Figure 1
Figure 2
Figure 3A~4
AI summary
A method for packing and a pack, for protecting in particular the lateral sides of ceramic flat tiles (2).