Foam Injector Array Packaging Liquid Foam Mold

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Solution Overview

Problem

In materials handling facilities, such as order fulfillment centers, the use of cardboard boxes and filler materials for packaging items is inefficient and generates waste, especially when packaging single items, as they do not effectively absorb shocks or vibrations during transport.

Innovation Solution

A system of liquid injectors that form a mold around the item using a settable liquid foam, such as biodegradable urethane foam, to create a robust and shock-absorbent packaging material, eliminating the need for cardboard boxes and reducing waste by using a spraying injection process that can encase items of up to 40 inches in size, with the foam being capable of retaining the shape of the mold and providing excellent vibration resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If cardboard boxes and filler materials are used for packaging items, then items are protected during transport, but waste is generated and packaging efficiency is reduced

Engineering Contradiction:

Improveprotection during transportVSAvoidwaste generation

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent applies parameter changes by transforming the packaging material from solid cardboard and loose filler into a liquid foam that can be injected and then solidifies. This phase change allows the material to conform precisely to the item being packaged, providing protection while eliminating excess material and waste.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes phase transitions by injecting liquid foam into the packaging cavity, where it expands and then solidifies into a rigid protective structure. This transition from liquid to solid state enables the packaging material to adapt to the item's shape and provide shock absorption without requiring pre-formed cardboard boxes or filler materials.

Inventive Principle:

Principle #36Phase transitions

2Reliability

If cardboard boxes and filler materials are used for packaging, then items are cushioned against shocks, but packaging complexity increases

Engineering Contradiction:

Improveshock absorptionVSAvoidpackaging structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges multiple packaging functions into a single material system. The liquid foam simultaneously provides shock absorption, structural support, and space-filling properties that previously required separate cardboard boxes and filler materials. This consolidation simplifies the packaging structure while maintaining protective capabilities.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs hydraulic principles by using liquid foam injection to deliver the packaging material. The liquid foam is pumped through injectors that distribute it evenly throughout the packaging cavity, allowing for automated and consistent packaging without complex manual assembly of cardboard and filler materials.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Reliability

If traditional packaging materials are used, then items are secured in the box, but vibration resistance is insufficient

Engineering Contradiction:

Improveitem securityVSAvoidvibration damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent utilizes composite materials by combining the properties of liquid foam that provides both cushioning and structural integrity. The foam's cellular structure offers vibration damping while its solidified form provides rigid support, creating a composite packaging solution that addresses both item security and vibration resistance simultaneously.

Inventive Principle:

Principle #40Composite materials

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 system effectively packages items without cardboard boxes, reducing waste and costs, while providing superior shock and vibration protection, as the liquid foam solidifies into a monolithic, seamless package that conforms to the item's shape, ensuring safe and efficient shipping.

Implementation Method 1

injecting liquid foam into the mold defined by the array and capable of solidifying into a solid foam construct

Methodology Applied

Scientific EffectPhase change (liquid to solid): Phase Change

Implementation Method 2

The liquid foam can be formed by mixing two constituent liquids together that react with one another and thereafter solidify into a solid foam construct

Methodology Applied

Scientific EffectFoam expansion: Foam

Data Source

PatentUS10343802B1Method of packaging an object using an array of foam injectors

Publication Date: 2019.07.09 AMAZON TECH INC

AI summary

A method of packaging an object includes positioning the object on an array of foam injectors, each of which is proximate at least one other foam injector in the array along a first direction and also abuts at least a second other foam injector in the array along a second direction substantially perpendicular to the first direction. Each foam injector in the array is configured to translate along a third direction that is substantially perpendicular to the first and second directions. The method includes translating a first subset of the foam injectors along the third direction so as to define a mold that surrounds the object with respect to the first and second directions and injecting liquid foam into the mold from a second subset of the foam injectors so as to enclose the object in liquid foam with respect to the first and second directions.