Flexible Bottom Layer Overhang for Pallet-Free Product Stack Packaging
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Solution Overview
Problem
Existing packaging methods for product stacks, such as stretch packing and foil sacks, often result in thermal damage, mechanical stress, contamination, and dirt exposure due to heat-induced shrinkage, mechanical instability, and inadequate underside protection during handling and transport.
Innovation Solution
A packaging method using a mechanically stable yet flexible material as the bottom layer with an overhang, which is larger than the product stack's diameter, and wrapped with stretch film to ensure comprehensive coverage and protection, reducing mechanical stress and contamination risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shrink film is used for packaging, then the packaging provides protection during shipping, but thermal damage occurs to temperature-sensitive goods
Solution Approach 1:
The harmful thermal shrinkage function is extracted from the packaging system. Instead of using heat-triggered shrink film, the patent uses mechanical stretch film that is applied cold and maintains its protective function without thermal damage to the product.
Solution Approach 2:
The patent uses a disposable stretch film packaging system that provides adequate protection without requiring the complex thermal recovery mechanisms of shrink film. The film is applied once and maintains protection throughout the shipping lifecycle.
2Object-affected harmful factors
If the bottom layer has a diameter larger than the product stack, then mechanical stress and contamination are reduced, but the blank becomes compressed and deformed
Solution Approach 1:
The patent changes the dimensional parameter of the bottom layer diameter to be slightly larger than the product stack diameter. This parameter optimization allows the bottom layer to extend beyond the stack edges, providing protective overhang that reduces mechanical stress and contamination while maintaining proper fit.
Solution Approach 2:
The bottom layer is intentionally made slightly larger than necessary (excessive action) to extend beyond the stack edges. This creates an overhang that provides additional protection against mechanical stress and contamination during handling and transport.
3Strength
If the stretch film is tensioned during overstretch, then the blank is secured to the product stack, but the film is cut open or the blank is deformed
Solution Approach 1:
The bottom layer is designed with extended diameter and overhang before the stretching process begins. This beforehand preparation creates a cushioning effect that distributes the tension loads during overstretch, preventing film cutting and blank deformation while maintaining secure anchoring.
4Stability of the object's composition
If the bottom layer is made rigid, then mechanical stability is improved, but flexibility and adaptation to diameter differences are reduced
Solution Approach 1:
The bottom layer is constructed as a composite structure combining rigid components (for mechanical stability) with flexible elements (for adaptability). This composite design allows the bottom layer to maintain its shape and provide structural support while simultaneously adapting to diameter variations and forming proper overhang.
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
The solution provides enhanced mechanical load-bearing capacity, reduces damage and contamination, and maintains product integrity by compensating for diameter differences and preventing bellows formation, ensuring effective protection during handling and transport.
Implementation Method 1
The outside (5) of the product stack (4) is wrapped during a so-called stretch process with individual layers of a highly extensible packaging film, the stretch film (2a)
Implementation Method 2
the overstretch (6) is mechanically destroyed by friction due to this shearing load
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The present invention relates to a pallet-free packaging of a product stack (4) consisting of a top layer (1), a bottom layer (3) and film layers (2) enclosing the product stack (4), wherein the film layers (2) fix the top layer (1) and the bottom layer (3) to the product stack (4), and wherein the bottom layer (3) consists of a flexible material (3a) and the bottom layer (3) encloses the edges of the product stack (4) with an overhang (7).