Automotive Hood Packaging With Segmented Side Rails

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Solution Overview

Problem

Vehicle hoods are frequently damaged during shipping due to inadequate support and packaging, leading to high damage rates and limitations in shipping distance and flexibility, which complicates logistics and increases costs, with many suppliers avoiding shipping due to these challenges.

Innovation Solution

A protective packaging system featuring slotted side rails, corrugated inserts, and foam spacers that securely encase the hood within a regular slotted carton, meeting industry standards and exceeding drop test requirements to prevent damage and extend shipping distances.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If hoods are shipped without substantial support and bracing, then shipping cost and complexity are reduced, but damage rate increases to over 25%

Engineering Contradiction:

Improveshipping simplicityVSAvoiddamage prevention

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The packaging system divides the hood support function into multiple independent components: side rails with slots, corrugated inserts, foam spacers, and buttressing members. Each component performs a specific support function, allowing the packaging to be assembled in a relatively simple manner while providing comprehensive protection against damage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The packaging system incorporates cushioning elements (foam spacers, corrugated inserts, and buttressing members) that are positioned in advance to prevent damage before it occurs. These elements are designed to absorb and distribute impact forces during shipping, addressing the damage prevention requirement proactively rather than reactively.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Productivity

If warehouses are reduced to save space and cost, then operational efficiency improves, but shipping distance limitations and damage risks increase

Engineering Contradiction:

Improvewarehouse efficiencyVSAvoidshipping safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The side rails feature curved or contoured surfaces that conform to the hood's shape, distributing contact forces more evenly across the hood surface. This curvature design enhances protection during transit while maintaining packaging efficiency.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Reliability

If packaging materials are not easily stored and assembled, then protection quality may improve, but storage utility and assembly efficiency decrease

Engineering Contradiction:

Improveprotection qualityVSAvoidassembly ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The packaging components are designed to nest within each other when not in use. The corrugated inserts and foam spacers can be stored within the side rails or carton structure, maximizing storage utility while maintaining protection quality.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Adaptability or versatility

If flexible packaging for different hood types is developed, then adaptability improves, but packaging complexity and assembly difficulty increase

Engineering Contradiction:

Improvehood type flexibilityVSAvoidpackaging structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The packaging system incorporates adjustable and reconfigurable elements that can adapt to different hood sizes and shapes. The side rails with slots allow for positioning adjustments, and the corrugated inserts can be configured in different patterns to accommodate various hood geometries, providing versatility without requiring completely different packaging for each hood type.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUSRE44083E1Protective package for an automobile part

Publication Date: 2013.03.19 BATAVIA CONTAINER

AI summary

A protective package for an automobile part; as assembled, packaged and buttressed for shipping; minimizes or eliminates damage to the automobile part being shipped, by providing a carton, side rail supports in the carton to receive the part and padded supports to secure the part in the carton.