Fluid Product Mailer for Automated USPS Shipping
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Solution Overview
Problem
Product manufacturers face high shipping costs when using private carriers, and there is a need for a cost-effective method to ship fluid products via the USPS First-Class mail, which requires non-rigid, machinable packaging that can conform to automated sorting systems.
Innovation Solution
A folded mailer system with a tri-folded structure that encloses a container, allowing it to be processed by automated mailing systems without human intervention, using a planar sheet with multiple layers to ensure flexibility and compliance with USPS machinable mail requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If private shipping carriers are used to provide door-to-door service, then delivery service quality is improved, but shipping cost increases significantly
Solution Approach 1:
The patent combines the fluid container with the mailing structure into an integrated fluid product mailer system. The container is positioned within a mailing structure that has a first portion and a second portion that can be folded together, merging the packaging and mailing functions into a single unit that meets USPS machinable requirements while maintaining product protection.
2Loss of energy
If USPS First-Class mail is used to reduce shipping cost, then shipping cost decreases, but packaging must meet stringent machinable requirements
Solution Approach 1:
The mailing structure is divided into a first portion and a second portion that can be folded together. This segmentation allows the structure to be configured in different states (open for filling, folded for mailing) and enables it to meet USPS machinable requirements when folded while providing adequate protection for the fluid container.
Solution Approach 2:
The mailing structure transitions between different configurations - an open state for filling the container and a folded state for mailing. The structure includes fold lines that enable it to be collapsed into a compact form that meets USPS size and shape requirements for machinable mail while maintaining structural integrity for product protection.
3Reliability
If a fluid container is made rigid to prevent leaking, then product protection is improved, but the container becomes non-machinable
Solution Approach 1:
The patent employs a flexible mailing structure with fold lines that can be bent and folded by automated mailing machinery. The structure includes a first portion and a second portion that fold together to enclose the fluid container, creating a protective envelope that is flexible enough for machine processing while still providing adequate protection against leakage during transit.
Data Source
AI summary
The assembly (1) has a plastic sachet (2) containing cosmetic product and enclosed within a paper card (3), where the sachet includes a wall and another wall (5b) with an annular attachment (6) and an opening unit (7), respectively. The card includes two walls (8a, 8b) with a closure device (9) and an opening unit (11). An adhesive fixes the sachet on the card, so that the assembly with the cosmetic product is generally planar so as to be collected, handled, transported, stored and distributed by mail while preserving integrity of the sachet and the dose of fluid product.