Foldable Cellulose Foam Packaging Insert With Hinged Cushioning
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Solution Overview
Problem
Existing packaging inserts made from foamed polymers, such as EPS, are not easily foldable and compromise cushioning or insulation capacity when compressed, especially at folds, making them ineffective for protecting goods from shock impact and providing thermal insulation.
Innovation Solution
A packaging insert design featuring multiple cellulose-based air-laid or solid foam substrates sandwiched between paper-based sheets, with hinge sections allowing easy folding without significant compression, ensuring continuous cushioning and insulation at folds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foamed polymer inserts (EPS) are used for cushioning and insulation, then protection capacity is improved, but foldability deteriorates
Solution Approach 1:
The packaging insert is divided into multiple separate substrates (first substrate, second substrate, third substrate) instead of using a single continuous foamed polymer piece. These substrates are arranged in sequence with spacing between them, allowing the structure to be flexible and foldable while each substrate maintains its cushioning and insulation properties independently.
2Ease of operation
If foamed polymer inserts are compressed at folds, then foldability is improved, but protection capacity deteriorates
Solution Approach 1:
A spacing element is introduced between the substrates to maintain a specific distance without requiring compression of the substrates themselves. The hinge section acts as an intermediary that enables folding motion while the substrates remain uncompressed, preserving their protective capabilities even at folded positions.
3Reliability
If thicker insulating material is used, then insulation capacity is improved, but foldability deteriorates
Solution Approach 1:
The packaging insert structure is designed to be dynamic rather than rigid. The hinge section enables the insert to change its configuration from a flat extended state to a folded state, adapting to different packaging space requirements while maintaining the thickness and insulation properties of the individual substrates.
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 folded to fit various packaging without compromising cushioning or insulation, effectively protecting goods from shock impact and providing thermal insulation, even at folds.
Implementation Method 1
the multiple cellulose-based air-laid or solid foam substrates are spaced apart from each other when the multiple sandwich sections are arranged one after another along a longitudinal axis of the packaging insert
Implementation Method 2
packaging insert suitable for protecting packaged goods from shock impact and/or for thermal insulation of packaged goods
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 main sides (22, 22A, 22B, 22C; 24, 24A, 24B, 24C). First and second paper-based sheets (30, 40) are attached to the first and second main sides (22, 22A, 22B, 22C; 24, 24A, 24B, 24C) so that the multiple cellulose-based air-laid or solid foam substrates (20, 20A, 20B, 20C) are sandwiched between the first and second paper-based sheets (30, 40) forming multiple sandwich sections (52, 52A, 52B, 52C). The multiple cellulose-based air-laid or solid foam substrates (20, 20A, 20B, 20C) are spaced apart from each other. A respective hinge section (50, 50A, 50B) is interposed between consecutive sandwich sections (52, 52A, 52B, 52C). The packaging insert (10) is foldable in the respective hinge section (50, 50A, 50B) and can be positioned within a packaging (80) to protect packaged goods.