Foldable Cellulose Foam Packaging Insert With Beveled Hinges
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing packaging inserts made from foamed polymers, such as expanded polystyrene, are not easily foldable to fit into various packaging, boxes, and containers, compromising their effectiveness in protecting goods from shock impact and thermal insulation at folds.
Innovation Solution
The packaging insert is designed with multiple cellulose-based air-laid or solid foam substrates having beveled edges forming angles less than 90°, allowing for easy folding at hinge sections without significant compression, maintaining cushioning and insulation capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If packaging inserts are made from thick foamed polymer materials to provide adequate cushioning and insulation, then protection performance is improved, but foldability and ease of insertion into packaging is worsened
Solution Approach 1:
The packaging insert is divided into multiple thin substrate layers (first substrate, second substrate, third substrate) instead of using a single thick layer. Each layer has a thickness of 0.5-5mm, and when stacked together they provide the required total thickness for protection while each individual layer remains flexible and easily foldable. The segments are connected via hinge sections that allow the multi-layer structure to be folded without compromising the cushioning performance of the foam materials.
2Reliability
If packaging inserts are made from traditional foamed polymers to provide cushioning and insulation, then protection performance is improved, but environmental sustainability is worsened
Solution Approach 1:
The invention changes the material parameter from conventional synthetic foamed polymers (EPS, EPE, EPP) to cellulose-based foam substrates. The cellulose foam has comparable density ranges (20-80 kg/m³) and can provide equivalent cushioning and thermal insulation properties while being biodegradable and environmentally sustainable. This parameter change maintains protection performance while eliminating the environmental harm associated with persistent plastic waste.
Solution Approach 2:
The packaging insert uses a composite structure combining multiple cellulose-based foam substrates with paper-based sheets. The cellulose foam substrates provide the cushioning and insulation core, while the paper-based sheets (attached to the outer surfaces) enhance structural integrity, surface protection, and biodegradability. This composite approach maintains protection performance while using entirely biodegradable materials to replace harmful synthetic polymers.
3Adaptability or versatility
If packaging inserts are folded to fit into various packaging containers, then adaptability is improved, but cushioning and insulation capacity at fold sections is worsened
Solution Approach 1:
The packaging insert incorporates hinge sections that enable dynamic folding between the rigid cellulose foam substrates. These hinge sections allow the insert to adapt its shape to fit various packaging containers (boxes, containers, envelopes) while maintaining the structural integrity and cushioning capacity of the foam materials. The hinges provide controlled flexibility, allowing the insert to bend without creasing or compressing the foam substrates at the fold locations, thereby preserving protection performance even when folded.
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 insert can be efficiently folded to fit into packaging without compromising cushioning or insulation, providing effective protection from shock impact and thermal insulation at folds.
Implementation Method 1
the use of plastic insulation and/or cushioning products has come more and more into question... for thermal insulation of packaged goods
Implementation Method 2
protecting the goods is to include cushioning and/or insulating products... for protecting packaged goods from shock impact
Data Source
AI summary
A packaging insert (10) comprises multiple cellulose-based air-laid or solid foam substrates (20, 20A, 20B, 20C) having respective first and second main sides (22, 22A, 22B, 22C, 24, 24A, 24B, 24C). The packaging insert (10) also comprises a first paper-based sheet (30) attached to the first main sides (22, 22A, 22B, 22C) and a second paper-based sheet (40) attached to the second main sides (24, 24A, 24B, 24C). Edges (26, 26A, 26B, 28, 28B, 28C) of consecutive cellulose-based air-laid or solid foam substrates (20, 20A, 20B, 20C) facing each other are beveled edges (26, 26A, 26B, 28, 28B, 28C) and form an angle (a) between each other that is less than 90°. At least one hinge section (50, 50A, 50B) is interposed between the beveled edges (26, 26A, 26B, 28, 28B 28C) of the consecutive cellulose-based air-laid or solid foam substrates (20, 20A, 20B, 20C). The packaging insert (10) is foldable in the hinge section(s) (50, 50A, 50B) and can be positioned within a packaging (80) to protect packaged goods. The invention also relates to a method of producing a packaging insert (10).