Gas Injected Auto-Dunnage Formation in Sealed Containers
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Solution Overview
Problem
Traditional methods of adding dunnage to shipping containers before closure often result in inadequate or excessive dunnage, leading to container bowing or item shifting during transport, which can cause damage.
Innovation Solution
A dunnage injection system that injects gas-filled polymer pouches into sealed containers to securely position and stabilize items by expanding to fill voids between the items and the container flaps, ensuring proper securing and protection during transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dunnage is added before container closure, then item protection is provided, but container bowing or item shifting occurs due to inadequate or excessive dunnage
Solution Approach 1:
The system performs preliminary actions by sealing the container with items inside first, then subsequently adding the exact amount of dunnage needed through injection ports. This reverse sequence allows precise control of dunnage quantity without risking container bowing or item shifting, as the dunnage is added only after the container structure is finalized.
Solution Approach 2:
The patent employs pneumatic injection systems to deliver gas-filled dunnage materials into the sealed container through injection ports. This pneumatic method enables precise control over dunnage expansion and quantity, ensuring optimal protection without excessive material that could cause container deformation.
2Manufacturing precision
If dunnage is added after container sealing, then precise dunnage quantity is achieved, but container penetration is required
Solution Approach 1:
The system segments the container wall by creating localized injection ports or penetration points that allow dunnage injection without compromising overall container integrity. These segmented access points enable precise dunnage delivery while maintaining the sealed environment for the items inside.
Solution Approach 2:
The patent uses intermediary injection ports or penetration devices that facilitate dunnage delivery into the sealed container. These intermediaries bridge the gap between the external dunnage supply system and the internal container environment, enabling controlled material transfer without breaking the seal.
3Ease of manufacture
If traditional dunnage methods are used, then simple process is maintained, but container bowing occurs
Solution Approach 1:
The system performs preliminary container sealing before dunnage addition, establishing the container's final structural configuration. This preliminary action prevents subsequent structural changes that could cause bowing, while the later dunnage injection occurs in a controlled manner that preserves container strength.
Solution Approach 2:
The pneumatic injection system delivers dunnage in a controlled, gradual manner that prevents sudden pressure changes or excessive force application. This controlled delivery mechanism protects container structural integrity while maintaining process simplicity.
Data Source
AI summary
Described are systems, methods, and apparatus for injecting dunnage into a container after an item has been placed in the container and the container has been sealed or otherwise closed. A dunnage injection apparatus is configured to penetrate a surface of the sealed container and expel gas and dunnage into an interior space of the container. The gas fills the expelled dunnage forming gas-filled pouches of dunnage that fill voids within the interior space of the container and secure and protect the item within the container.