Frangible Web for Dunnage Inflation
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Solution Overview
Problem
Existing plastic web technologies for forming dunnage units from sheets of plastic often result in undesirable inflation-induced stresses and wrinkles due to unrestrained pouch sides, leading to compromised seals and potential leaks, as the sides of adjacent pouches are connected by perforations that extend along their entire length.
Innovation Solution
A plastic web with spaced transverse seals and a frangible connection near the inflation edge, allowing for inflation and separation of pouches with a gap forming area that reduces foreshortening stresses and facilitates fuller inflation, enabling easier separation and more reliable sealing of dunnage units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If perforations extend all the way to the inflation edge of the web, then the pouches can be easily separated, but inflation-induced stresses and wrinkles increase causing compromised seals and potential leaks
Solution Approach 1:
The frangible connection is segmented into two distinct parts: (1) a first frangible portion extending from the inflation edge inward a first distance, and (2) a second frangible portion extending from the inflation edge inward a second distance greater than the first distance. This segmentation allows the connection to break at different locations depending on inflation forces, enabling easy separation while maintaining seal integrity during the inflation process.
Solution Approach 2:
Different portions of the frangible connection have different fracture strengths and break at different locations. The first frangible portion has greater fracture strength than the second frangible portion, creating local variations in mechanical properties that allow controlled breaking behavior during inflation while maintaining overall connection integrity when needed.
2Stability of the object's composition
If the sides of adjacent pouches are connected by perforations along their entire length, then the pouches remain constrained during handling, but inflation-induced stresses cause wrinkles and compromised seals
Solution Approach 1:
The frangible connection transitions from a static constrained state to a dynamic broken state during inflation. The connection remains intact during handling and inflation to maintain pouch alignment, then dynamically breaks at the appropriate frangible portion to release stresses and prevent wrinkles, ensuring high-quality seals.
3Ease of operation
If a frangible connection is placed close to the inflation edge, then separation is easier, but the connection may break during inflation causing premature separation
Solution Approach 1:
The frangible connection is divided into two segments at different distances from the inflation edge, creating a hierarchical breaking structure. The first frangible portion breaks more easily for simple separation tasks, while the second frangible portion provides additional strength to prevent premature breaking during the inflation process.
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 solution reduces undesirable stresses during inflation, prevents wrinkles, and results in more reliable seals and easier separation of dunnage units, enhancing the efficiency and effectiveness of the dunnage unit formation process.
Implementation Method 1
A frangible line of connection is disposed in one superposed layers of the tube proximate to the inflation edge. This frangible connection may be broken to permit inflation of the inflatable pouches.
Data Source
AI summary
An elongate flattened thermoplastic tube has an inflation edge and an opposite edge. The tube includes spaced transverse seals that define sides of pouches. The tube includes lines of weakness that allow adjacent dunnage units to be separated. A frangible line of connection is disposed in one two superposed layers of the tube proximate to the inflation edge. This frangible connection may be broken to permit inflation of the inflatable pouches.