Fluid-Filled Packaging Pads for Impact Protection
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Solution Overview
Problem
Conventional packaging for voluminous electrical appliances is energy-intensive to manufacture, costly to transport due to low density, and challenging to recycle, with existing solutions not being adaptable to the shape and size of the objects they protect, and often requiring separate facilities for production and storage.
Innovation Solution
A packaging system comprising multilayer plastic films with transverse and longitudinal joint lines forming fluid-filled pads, which can be configured to fit the object's shape and size, allowing for on-site manufacturing and easy recycling, using a process that involves shaping, filling, and folding to create protective covers that adapt to the object's surface details.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If conventional packaging (cardboard/EPS) is used, then protection is provided, but manufacturing energy consumption is high and transport cost per kilogram is high
Solution Approach 1:
The patent changes the physical state of the packaging material from solid foam (EPS) or rigid cardboard to a flexible film structure that is inflated with air to create protective pads. This parameter change from solid to aerated structure reduces manufacturing energy and material density while maintaining protection capability through the air-filled pads that cushion impacts.
Solution Approach 2:
The packaging film transitions from a flat, compact state during transport to an inflated, three-dimensional protective structure when air is introduced. This phase transition allows the same material to occupy minimal space during logistics and expand to provide full protective coverage when needed, reducing both manufacturing energy and transport costs.
2Reliability
If low-density packaging (EPS/cardboard) is used, then protection is provided, but transport cost per kilogram is high
Solution Approach 1:
The patent uses pneumatic inflation of the packaging film with air to create protective pads. The air-filled structure provides cushioning and impact protection equivalent to or better than solid foam, while the negligible weight of air compared to EPS or cardboard dramatically reduces the weight being transported, lowering transport cost per kilogram.
Solution Approach 2:
The patent employs thin flexible plastic films that can be inflated to form protective structures. These thin films have minimal weight compared to solid packaging materials, yet when inflated create robust protective pads that maintain protection capability while significantly reducing the weight and transport cost.
3Adaptability or versatility
If custom-shaped packaging is used, then protection adapts to object, but manufacturing complexity increases requiring metal moulds
Solution Approach 1:
The patent uses dynamically inflatable pads that can be adjusted in volume and shape after manufacturing. Instead of creating custom-shaped rigid packaging for each object, the system uses flexible films that can be inflated to conform to various object shapes, allowing a single manufacturing process to produce adaptable packaging for different product geometries without requiring complex metal moulds.
Solution Approach 2:
The packaging system divides the protective structure into multiple independent inflatable pads rather than using a single custom-molded piece. Each pad can be independently manufactured from standard film and then inflated to fit specific protection zones on the object, simplifying manufacturing while maintaining adaptability to complex object shapes.
4Reliability
If pre-manufactured packaging is used, then protection is provided, but storage and transportation facilities are required
Solution Approach 1:
The packaging films are supplied in compact rolled form that nests efficiently during storage and transport. When needed, the rolls are unrolled and inflated to form the protective structure. This nesting approach minimizes the space required for storing and transporting the packaging material compared to pre-inflated or rigid packaging, reducing the quantity of storage and transportation resources needed.
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
This solution reduces raw material usage and transportation costs, enhances protection against impacts and vibrations, and facilitates easier recycling by allowing the packaging to be made where needed, reducing storage and transportation needs.
Implementation Method 1
the two stacked layers of film are joined by transverse and longitudinal joint lines, these joint lines preferably made using heat sealing
Implementation Method 2
creating pads of different sizes which are filled with fluid to protect the aforesaid objects or appliances from rubbing, knocks and/or vibrations
Data Source
Figure 1~3
Figure 4a~4c
Figure 5~7
AI summary
The invention relates to a packaging consisting of a cover (20) obtained from a packaging sheet (22) obtained from a film (23), with transverse (30) and longitudinal (31) joining lines, in order to establish therebetween pads (32) which are filled with a fluid (33), in order to protect an object (21) to which the protective cover (20) is applied on the outside in a fitted manner. The cover (20) can have the pads (32) thereof closed or open (34) and communicating with one another, allowing the fluid to pass through. The packaging sheet (22) also has folding areas (35) allowing same to be adapted to the contour or the shape of the object to be protected (21), also having hollow areas (36) for adapting to the surface of the object to be protected (21), including closing areas (37) for closing the sheet (22) onto itself, being fitted to the object to be protected.