On-demand inflatable packaging web with preformed pouches

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Solution Overview

Problem

Conventional padded envelopes are manufactured in a fully inflated state, leading to inefficiencies in shipping and storage, as they occupy more volume and weight than necessary, and do not allow for just-in-time production of inflated packaging materials.

Innovation Solution

A method for producing on-demand inflatable packaging that includes a web of preformed pouches with an outer skin, where the pouches are defined by side edges and panels with an inflation pattern, allowing for delayed inflation, enabling more efficient shipping and production by inflating only what is needed at the point of use.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If padded envelopes are manufactured in a fully inflated state, then the cushioning material provides effective protection for products, but the shipping volume and weight increase significantly

Engineering Contradiction:

Improvecushioning effectivenessVSAvoidshipping volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The packaging system is divided into two separate components: a flat, compact outer envelope and an separate inflatable cushioning material. The cushioning material is stored in a deflated state within the envelope and only inflated when needed at the point of use, allowing the envelope to ship in a compact form while providing full cushioning protection when activated.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cushioning material transitions from a static, flat state during shipping to a dynamic, inflated state at the point of use. This dynamic transformation allows the packaging to optimize its volume during transport and then expand to provide the necessary protective cushioning when the product is being packaged.

Inventive Principle:

Principle #15Dynamics

2Ease of operation

If padded envelopes are manufactured in a fully inflated state, then the cushioning material is ready for immediate use, but the storage space and inventory costs increase

Engineering Contradiction:

Improvereadiness for useVSAvoidstorage volume

Core Design Contradiction:

Ease of operationVSVolume of stationary object

Solution Approach 1:

The envelope structure and inflatable cushioning material are prepared in advance in a compact, deflated state. The cushioning material is pre-positioned within the envelope in a space-efficient form, and all necessary components are assembled before shipping. When needed, the cushioning material is quickly inflated at the point of use, providing ready-to-use protection without requiring large storage volumes.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If conventional padded envelopes are used, then the cushioning material is pre-formed and sealed, but the production process lacks flexibility and timing control

Engineering Contradiction:

Improveproduction efficiencyVSAvoidjust-in-time production capability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The system enables dynamic production timing by separating the manufacturing of the envelope structure from the inflation of the cushioning material. The envelope can be manufactured and shipped in a flat state, and the cushioning material is inflated only when needed at the point of use, allowing for just-in-time production and eliminating the need for large inventories of pre-assembled padded envelopes.

Inventive Principle:

Principle #15Dynamics

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

This approach allows for reduced shipping volume and weight of non-inflated envelopes, enabling just-in-time production of inflated packaging, minimizing inventory and optimizing storage and shipping costs while maintaining effective cushioning for products.

Implementation Method 1

a small amount of air is trapped within each cell to create a cushioning characteristic

Methodology Applied

Scientific EffectGas expansion:

Data Source

PatentUS11801988B2On-demand inflatable packaging

Publication Date: 2023.10.31 SEALED AIR U S

AI summary

An inflatable packaging web (3201) includes a continuous web of preformed pouches (3200) and an outer skin (612). The continuous web of preformed pouches is defined by two panels (18) connected together along first and second side edges (14) and either connected together or folded along a bottom edge (20). At least one of the panels is inflatable. The outer skin is disposed over at least one of the inflatable panels. The outer skin is attached to the at least one of the inflatable panels along at least a portion of the height of the first and second side edges. The preformed pouch includes at least one fold such that a folded portion (3215) of the two panels is folded over a first portion of the two panels.