Flexible Container Gusset Design for Structural Integrity

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Solution Overview

Problem

Conventional rigid containers for fluent products are expensive to produce, require significant materials, are difficult to decorate, prone to damage, and challenging to dispense from, due to their rigid nature.

Innovation Solution

Flexible containers made from materials that can be easily formed into shapes with novel support structures, allowing for reduced material usage, easier decoration, and improved dispensing capabilities while maintaining structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If rigid materials are used for container construction, then structural integrity is improved, but material cost and quantity increase

Engineering Contradiction:

Improvestructural integrityVSAvoidmaterial quantity

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The patent applies flexible packaging materials (films and foils) instead of rigid materials to construct the container body. The flexible material is formed into a container shape with integrated gusset panels that provide structural support, eliminating the need for thick rigid walls while maintaining strength. This resolves the contradiction by using thin flexible films rather than bulky rigid materials.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The container is segmented into distinct functional panels: side panels for containment, gusset panels for structural support and expansion, and bottom panels for stability. This segmentation allows each panel to be optimized for its specific function, with gusset panels providing the necessary strength through their folded geometry rather than material thickness.

Inventive Principle:

Principle #1Segmentation

2Strength

If rigid materials are used for container construction, then structural integrity is improved, but manufacturing cost increases

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent uses flexible packaging materials that can be thermally sealed and formed using standard flexible packaging manufacturing equipment. The container is made from continuous rolls of flexible material that are sealed, formed, and cut in a continuous process, which is more cost-effective than molding rigid plastics or forming metal containers.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The container incorporates expandable gusset panels that can be collapsed during shipping to reduce volume, then expanded during use to provide structural integrity. This dynamic transformation allows the same structure to serve different functions at different times, reducing the need for permanently rigid construction.

Inventive Principle:

Principle #15Dynamics

3Strength

If rigid materials are used for container construction, then structural integrity is improved, but ease of dispensing deteriorates

Engineering Contradiction:

Improvestructural integrityVSAvoidease of dispensing

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The flexible container walls can be easily compressed and deformed by hand pressure to dispense contents. The flexible material allows the container to be squeezed, pressed, or manipulated in various ways to control product flow, unlike rigid containers that require openings or mechanical dispensing mechanisms.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The container transitions from a rigid, fixed-volume structure to a dynamic,可变-volume structure that can be easily compressed and deformed. The flexible walls allow the container to change shape during dispensing operations, enabling easy manual operation while maintaining structural integrity when needed.

Inventive Principle:

Principle #15Dynamics

4Strength

If rigid materials are used for container construction, then structural integrity is improved, but resistance to damage deteriorates

Engineering Contradiction:

Improvestructural integrityVSAvoiddamage susceptibility

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The flexible container material can absorb impacts and deformations without cracking or breaking like rigid materials. The flexible film can stretch, bend, and return to its original shape, providing resistance to damage from drops, crushing, and other handling abuses that would damage rigid containers.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible container structure inherently provides cushioning against impacts and crushing forces. The flexible material acts as a shock absorber, deforming under impact forces to protect the contents, whereas rigid containers would transmit these forces directly to the contents or break themselves.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentEP3066025B1Method of forming a flexible container

Publication Date: 2019.06.19 PROCTER & GAMBLE CO

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AI summary

A method of forming a flexible container can include folding a web or sheet to define one or more gussets in one or more regions of the flexible container. The gusset can be a continuous gusset or can be an interrupted gusset, having a seal disposed in the gusset.